CN108697560B

CN108697560B - Absorbent article

Info

Publication number: CN108697560B
Application number: CN201780012786.0A
Authority: CN
Inventors: J.L.哈蒙斯; K.A.阿罗拉; S.N.莫斯; M.O.阿维莱斯; O.E.A.伊塞勒
Original assignee: Procter and Gamble Co
Current assignee: Procter and Gamble Co
Priority date: 2016-03-09
Filing date: 2017-03-09
Publication date: 2022-04-15
Anticipated expiration: 2037-03-09
Also published as: EP3426211A1; CA3014673C; JP2020157097A; EP3426211B1; JP2019507641A; CA3014673A1; ES2875839T3; CN108697560A; BR112018067962A2; BR112018067962B1; WO2017156208A1; US20170258651A1; MX2018010837A; HUE054574T2; IL261302A

Abstract

Disclosed herein are absorbent articles comprising a web of material. The web materials described herein can provide a variety of benefits when used in the context of absorbent articles, and such web materials can facilitate the manufacture of absorbent articles.

Description

Absorbent article

Technical Field

The present disclosure relates generally to webs of material and articles incorporating webs of material.

Background

In recent years, nonwoven webs have been used in a wide variety of disposable absorbent articles. For example, in some particular absorbent articles, such as diapers and feminine pads, the nonwoven fabric may be used as the topsheet, backsheet, or some other feature of these particular absorbent articles.

Unfortunately, the requirements for absorbent articles may vary depending on the application. For example, nonwoven webs used as topsheets for baby diapers may not be suitable for use in adult incontinence products. Similarly, nonwoven webs suitable for use as topsheets for adult incontinence products may not be suitable for feminine pads.

In addition, the requirements for nonwoven webs in disposable absorbent articles may also vary from region to region. For example, in one area, absorbent articles with soft topsheets may be the first factor in the mind of consumers. In another area, minimizing the amount of rewet may be the first consideration in the mind of consumers. In yet another area, the speed of collection of liquid insult may be the first consideration in the mind of consumers.

It would be beneficial to have a web of material that addresses one or more of the above considerations. It would also be beneficial to have a process that facilitates producing a web of material that addresses one or more of the above considerations.

Disclosure of Invention

Disclosed herein are webs of material that can include spunbond webs of material, meltblown webs of material, and combinations thereof that can be used in disposable absorbent articles. Some exemplary uses include a topsheet, an acquisition layer, or an overwrap for a tampon. When used as a topsheet for feminine hygiene articles or other absorbent articles, for example, the web material of the present invention can provide a soft feel to the user and can provide rapid acquisition of menses and/or urine insults. Other benefits and configurations of these and other disposable absorbent articles are discussed below.

Drawings

While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter of the present invention, it is believed that the invention will be more readily understood from the following description taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a schematic representation of a cross-section of a web material of the present invention.

Fig. 2 is a schematic view of a process for making a spunmelt nonwoven web of the present invention.

Fig. 3A-3C are schematic cross-sectional views of bicomponent filaments useful in the present invention.

Fig. 4A is an illustration of an exemplary straight filament.

Fig. 4B is an illustration of an exemplary coiled filament.

Fig. 5A is a schematic view of a web material of the present invention shown in plan view.

FIG. 5B is a schematic view of the web material of FIG. 5A shown in cross-section along line 5B-5B.

FIG. 5C is a schematic view of the web material of FIG. 5A shown in cross-section along line 5C-5C.

Fig. 5D is a schematic view of another form of the web material of fig. 5A, shown in cross-section.

Fig. 5E is a schematic view of another form of the web material of fig. 5A, shown in cross-section.

Fig. 6A-6E are schematic illustrations of a tunnel cluster on a web of material of the present invention.

Fig. 7A-7D are schematic illustrations of packed clusters on a web material of the present invention.

Fig. 8A is a plan view photomicrograph showing one side of a web of material having three-dimensional discontinuities formed therein in accordance with the present disclosure.

Fig. 8B is a plan view photomicrograph showing the other side of the web material of fig. 8A with openings.

Fig. 8C is a perspective view of a discontinuity in a two-layer web material according to the present disclosure.

Fig. 8D is a schematic diagram of a nested cluster according to the present disclosure.

Fig. 9A-9D are schematic illustrations of corrugations and grooves in a web material of the present invention.

Fig. 10-14 are schematic views of disposable absorbent articles comprising multiple zones according to the present invention.

Fig. 15A-15B are SEM photographs of a first plurality of filaments of a first layer and a second plurality of filaments of a second layer, respectively.

Fig. 15C is an SEM photograph of a web material constructed according to the present invention.

Fig. 16A is a photograph of a web material comprising apertures, wherein the web material is constructed according to the present invention.

Fig. 16B is a photograph of a nonwoven laminate comprising a hydrophobic first layer and a hydrophilic second layer.

Fig. 17A is a photograph of a web of material including a tunnel bank, wherein the web of material is constructed according to the present invention.

Fig. 17B is a photograph of a nonwoven laminate comprising a hydrophobic first layer and a hydrophilic second layer.

Fig. 18 is a diagram of a coordinate system for a web material of the present invention.

Fig. 19-32 are photographs of a web of material including patterned apertures according to the present invention.

Fig. 33 shows a plan view of a feminine hygiene pad constructed in accordance with the present disclosure.

Fig. 34 shows a plan view of a diaper constructed in accordance with the present disclosure.

FIG. 35 shows a cross-section of the diaper of FIG. 34 taken along line 35-35.

Figure 36 shows a cross-section of the diaper of figure 35 in an expanded state.

Fig. 37 is an isometric view of an exemplary web of material with corrugations therein constructed according to the present disclosure.

Fig. 38 is an isometric view of an exemplary web of material with corrugations therein constructed according to the present disclosure.

Fig. 39 is an isometric view of an exemplary web of material with corrugations therein constructed according to the present disclosure.

Fig. 40 is a cross-sectional view of a web material in a three-layer configuration according to the present disclosure.

Fig. 41 is a perspective view of the web of material of fig. 40 with various portions of the nonwoven composition layers cut away to show the composition of each nonwoven composition layer according to the present disclosure.

Fig. 42 is a cross-sectional view of a web material in a four-layer configuration according to the present disclosure.

Fig. 43 is a perspective view of the web of material of fig. 42 with various layers of the web of material cut away to show the composition of each nonwoven layer in accordance with the present disclosure.

Fig. 44 is a schematic representation of a cross-section of a web material of the present invention.

Detailed Description

As used herein, "disposable absorbent article" or "absorbent article" will be used to refer to articles such as diapers, training pants, diaper pants, refastenable pants, adult incontinence pads, adult incontinence pants, feminine pantiliners, tampons, and pessaries. The term "disposable article" will be used to refer to articles such as face masks. For ease of discussion, the terms "disposable absorbent article" or "absorbent article" will be used; however, unless otherwise indicated, the web material of the present invention is equally useful in face masks.

As used herein, "hydrophilic" and "hydrophobic" have well-accepted meanings in the art with respect to the contact angle of a reference liquid on the surface of a material. Thus, materials having a liquid (water) contact angle greater than about 90 degrees are considered hydrophobic, and materials having a liquid (water) contact angle less than about 90 degrees are considered hydrophilic. A hydrophobic composition will increase the contact angle of water on the surface of the material, while a hydrophilic composition will decrease the contact angle of water on the surface of the material. Nonetheless, references to relative hydrophobicity or hydrophilicity between one or more materials and/or one or more compositions do not imply that the materials or compositions are hydrophobic or hydrophilic. For example, the composition may be more hydrophobic than the material. In such cases, neither the composition nor the material may be hydrophobic; however, the contact angle of a water drop on a composition is larger than the contact angle of a water drop on a material. As another example, the composition may be more hydrophilic than the material. In such cases, neither the composition nor the material may be hydrophilic; however, the contact angle with respect to a water droplet exhibited by the composition may be less than the contact angle exhibited by the material.

As used herein, "spunbond filaments" refers to small diameter filaments formed by the following process: the molten thermoplastic material is extruded from a plurality of fine capillaries of a spinneret as filaments, and the extruded filaments are then rapidly reduced in diameter. Spunbond filaments are generally not tacky when they are deposited onto a collecting surface. Spunbond filaments are generally continuous and have an average diameter (from a sample of at least 10 measurements) of greater than 7 microns, more particularly between about 8 and 40 microns.

The term "filament" refers to any type of artificial continuous strand produced by the process of: a spinning process, a melt blowing process, a melt fibrillation or film fibrillation process, or an electrospinning production process, or any other suitable process for preparing filaments. In the context of filaments, the term "continuous" is distinguishable from short length fibers, in that short length fibers are cut to a particular target length. In contrast, "continuous filaments" are not cut to a predetermined length; instead, they can break at random lengths, but are typically much longer than short length fibers.

By "substantially randomly oriented" is meant that due to the processing conditions of the process of laying a plurality of filaments onto a collecting surface (e.g., a moving porous belt with vacuum suction below) to form a nonwoven web, those filaments are settled down and tipped over onto the collecting surface following a turbulent, chaotic, random motion so that the direction of a length of filaments can be into any direction on a 360 ° circle-such as the lay direction. The lay down orientation may be more commonly in the Machine Direction (MD) than in the Cross Direction (CD), or vice versa, as may be analyzed via a histogram of fiber orientation distribution.

The web material of the present invention comprises at least two layers. As used herein, the term "layer" refers to a layered region that constitutes a unitary structure, which in the context of the present invention is a web of material. The combination of layers of the web material is not an assembly or laminate that forms the pre-formed layers of the multi-layer structure. Rather, the web material of the present invention is constructed by assembling the layers in a unitary manner as described herein. In some forms in which adjacent layers are not distinguishable, the adjacent layer may be considered one layer.

The concepts and techniques described herein for forming the material web of the present invention can be applied to spunbond filaments and/or fine fiber/nanofiber webs with multiple layers; which in turn may be included in the spunmelt web. The technique of spinning continuous and short fibers of molten material, and generally thermoplastics, is commonly referred to as the spunmelt technique. Spunmelt techniques may include both meltblown and spunbond processes. The spunbond process involves providing a molten polymer which is then extruded under pressure through a large number of orifices in a plate known as a spinneret or die. The resulting continuous fibers are quenched and drawn by any of a number of methods, such as, for example, slot draw systems, attenuation guns, or godet rolls. In the spinning process or spunbond process, the continuous fibers are collected as a loose web on a moving foraminous surface, such as, for example, a wire mesh conveyor belt. When more than one spinneret is used in a row to form a multi-layer web, subsequent layers of nonwoven composition are collected on the uppermost surface of the previously formed nonwoven composition layer.

As used herein, "fine fibers" and "nanofibers" will be used synonymously and refer to filaments or fibers having a diameter of less than about 8 microns. For example, meltblown filaments may have a diameter between 2 and 8 microns, while other filament preparation methods may produce sub-micron diameter filaments, as discussed below.

Methods of making fine or nano fibers include melt fibrillation and electrospinning. Melt fibrillation is a general class of making fibers defined as where one or more polymers are melted and extruded into a variety of possible configurations (e.g., co-extrusion, homogeneous or bicomponent films or filaments) and then fibrillated or fiberized into filaments. The meltblowing process is one such specific process (as described herein).

The meltblown process is associated with a spunbond process for forming a layer of nonwoven material in which a molten polymer is extruded under pressure through orifices in a spinneret or die. As the fibers exit the die, the high velocity gas impinges on and attenuates them. The energy of this step causes the diameter of the formed fibers to be greatly reduced and thus to be broken up in order to produce microfibers of indefinite length. This is different from the spunbond process, in which the continuity of the fibers is generally maintained. Meltblown nonwoven structures are often added to spunbond nonwoven structures to form spunbond-meltblown ("SM") webs or spunbond-meltblown-spunbond ("SMs") webs, which are strong webs with certain barrier properties. Coaxial meltblowing is known in the art and is considered a form of meltblowing.

Melt film fibrillation is another method that can be used to produce nanofibers, i.e., sub-micron fibers. A melt film is produced from the melt, and then a fluid is used to form fibers from the melt film. Examples of such methods include U.S. Pat. nos. 6,315,806, 5,183,670, and 4,536,361 to Torobin et al; and U.S. Pat. Nos. 6,382,526, 6,520,425, and 6,695,992 to Reneker et al, assigned to University of Akron; and U.S. patent 8,395,016; 8,487,156, respectively; 7,291300, respectively; 7,989,369, respectively; and 7,576,019. The Torobin process uses one or a series of co-annular nozzles to form a tube of film that is fibrillated by high velocity air flowing within the annular film. Other melt film fibrillation processes and systems are described in 2008/0093778 to Johnson et al, published 24.4.2008, us patent 7,628,941 to Krause et al, and us patent publication 2009/0295020 to Krause et al, published 3.12.2009, and provide uniform and narrow fiber distribution, reduced or minimal fiber defects such as unfiberized polymer melt (commonly referred to as "fines"), fly and dust. The methods and systems also provide a uniform nonwoven web for an absorbent hygiene article.

Electrospinning is another common method for producing sub-micron fibers. In this method, the polymer is typically dissolved in a solvent and placed in a chamber that is sealed at one end and has a small opening in the necked down portion at the other end. A high potential is then applied between the polymer solution and the collector near the open end of the chamber. The production speed of the process is slow and the fibers are typically produced in small batches. Another spinning technique for producing submicron fibers is solution spinning or flash spinning with a solvent.

Thus, in the context of the web material of the present invention, the first nonwoven layer may be integrally formed with the second nonwoven layer. However, the web material of the present invention is not limited to nonwoven fabrics. In addition, the web material of the present invention may further comprise a film layer in combination with the above-described nonwoven layer.

An exemplary web is shown in fig. 1. As shown in FIG. 1, the web material 10 of the present invention has a Machine Direction (MD) (perpendicular to the plane of the sheet shown in FIG. 1), a cross-machine direction (CD), and a Z-direction (thickness direction), as is well known in the web manufacturing art. As shown, the web material 10 includes at least a first layer 20 and a second layer 30. The web material 10 also includes a first surface 50 and a second surface 52. As discussed herein, the first layer 20 and the second layer 30 are integrally formed. For example, the first and second layers 20, 30 may be integrally formed via a spunmelt process, a meltblown process, or an electrospun process as described herein.

Additionally, in some forms of the invention, each of the first and second layers 20, 30 includes a plurality of randomly oriented filaments. For example, the first layer 20 may comprise a first plurality of randomly oriented filaments and the second layer 30 may comprise a second plurality of randomly oriented filaments. For ease of visualization, a boundary 54 is shown between the first layer 20 and the second layer 30; however, because the first and second layers 20, 30 are integrally formed, as described herein, the demarcation between adjacent layers may be less readily perceptible. However, as previously described, in some forms, the first layer 20 or the second layer 30 may comprise a film.

For the web material 10 of the present invention, the first layer 20 is different from the second layer 30. As shown in fig. 1, such configurations produce Z-direction feature differences, which can be measured as disclosed herein. In creating the Z-direction feature difference, the first layer 20 may differ from the second layer 30 in a number of ways. Some suitable examples include surface energy, thickness, filament diameter, filament cross-sectional area, filament cross-sectional shape, filament cross-sectional configuration with multiple polymers (e.g., "bicomponent"), filament crimp, and/or filament composition, softness, coefficient of friction, ductility, and/or color. Each of the foregoing represents a feature of a layer filament or of the layer itself. And these items are discussed in more detail below.

Each of these variables can affect the performance attributes of the absorbent article in various ways. For example, acquisition speed, reduction in rewet, creation of barrier properties, better conformability of the product, increase in softness, etc.

Additionally, the web material 10 of the present invention may also include MD and/or CD characteristic differences, which may be measured as disclosed herein. In creating the MD and/or CD characteristic differences, the first layer 20 and/or the second layer 30 may include a plurality of features. For example, holes, bond sites, embossments, tunnel tufts, infill tufts, nested tufts, outer tufts, and corrugations can provide MD and/or CD characteristic differences.

Web material-Z direction characteristic difference

Modifying the layer characteristics, as described above, can create Z-direction characteristic differences in the web material 10, which can enhance certain properties of the web material 10. For example, acquisition time, rewet, permeability, softness, masking, resiliency, and capillarity are some of the characteristics that can be modified based on the difference between the first and second pluralities of filaments. The differences between the first and second layers 10, 30 are discussed below along with the benefits of the web material properties.

Referring now to fig. 1 and 2, a web of material of the present invention can be prepared via a spunbond process comprising a plurality of spin beams 255, 257. In some forms, first manifold 255 may deposit a first plurality of filaments 261 onto the belt. Second spin box 257 can deposit a second plurality of filaments 263 onto the belt, over the top of first plurality of filaments 261. And as previously described, the second plurality of filaments may be configured differently than the first plurality of filaments such that the first layer 20 is different from the second layer 30.

A form of the invention is envisaged in which an additional spinning beam is provided to provide an additional layer with additional filaments. Thus, the web material of the present invention can include a third layer, a fourth layer, and the like. And the web of material layers may also be configured such that at least two of the layers are different. Additionally, forms of the invention are also contemplated in which the process for the web of material may allow for the inclusion of one or more nanofiber layers, such as one or more meltblown layers, one or more melt fibrillated layers, and/or one or more electrospun layers.

In addition, forms of the invention are also envisaged in which the first layer 20 is produced in a first step and subsequently processed. Subsequently, a second layer 30 may be deposited onto the first layer 20. For example, a first layer may be provided to an opening process (described herein), and then a second layer may be integrally formed on the first layer via the process described herein. As another example, the first layer may include a film. The first layer may be subjected to an opening process (described herein), and then the second layer may be integrally formed on the first layer via the process described herein. As another example, a first layer may comprise a nonwoven fabric subjected to an aperturing process (described herein), and then a second layer comprising a film is integrally formed on, e.g., extruded onto, the first layer. And as yet another example, the first layer and the second layer may be integrally formed without any intermediate processing of the first layer or the second layer.

Surface energy of

One of the ways to create Z-direction characteristic differences in the web material of the present invention is to use different surface energies for the first layer 20 and/or the second layer 30 (and/or any additional layers). Generally, a nonwoven layer having a high surface energy can be considered to be more hydrophilic than a nonwoven layer having a low surface energy. In other words, in some forms of the invention, the first layer 20 may be more hydrophobic than the second layer 30. Thus, in some forms, the first layer 20 may have a lower surface energy than the second layer 30.

The increased hydrophobicity of the first layer 20 (relative to the second layer or any other layer) may be achieved in a variety of ways. For example, the first plurality of filaments may comprise a composition that is more hydrophobic than the second plurality of filaments. In one particular example, the first plurality of filaments may comprise polyethylene and the second plurality of filaments comprises polyethylene terephthalate. Generally, polyethylene and polypropylene are more hydrophobic than polylactic acid, polyethylene terephthalate, and nylon. The first plurality of filaments and/or the second plurality of filaments can be any suitable combination of these compositions.

In another example, the first plurality of filaments and/or the second plurality of filaments may comprise a melt additive. In one particular example, the first plurality of filaments may comprise a hydrophobic melt additive added directly to or as a masterbatch into the polymer melt during spinning of the first plurality of filaments. Such melt additives may include, for example, a lipid ester or a polysiloxane. For those forms in which the additive is melt blended into the filaments, the additive may aggregate to the surface of the filaments and produce a film that covers a portion of the outer surface of the filaments, and/or may produce fibrils, flakes, particulates, and/or other surface features. The second plurality of filaments may comprise a hydrophilic melt additive in combination with or independent of the hydrophobic melt additive. In another example, the first plurality of filaments may include a hydrophobic melt additive at a first weight percent and the second plurality of filaments may include a hydrophobic melt additive at a second weight percent. The first weight percent may be greater than the second weight percent such that the first layer 20 is more hydrophobic than the second layer 30. In yet another example, the first plurality of filaments may include a hydrophilic melt additive at a first weight percent and the second plurality of filaments may include a hydrophilic melt additive at a second weight percent. In such forms, the second weight percentage may be greater than the first weight percentage such that the second layer 30 is more hydrophilic than the first layer 20. In yet another example, the first plurality of filaments may comprise a first hydrophobic melt additive and the second plurality of filaments comprises a second hydrophobic melt additive. In such forms, the first hydrophobic melt additive may render the first plurality of filaments more hydrophobic than the second plurality of filaments; or vice versa. In yet another example, the first plurality of filaments may comprise a first hydrophilic melt additive and the second plurality of filaments comprises a second hydrophilic melt additive. In such forms, the first hydrophilic melt additive may render the first plurality of filaments more hydrophilic than the second plurality of filaments; or vice versa.

For those forms in which the melt additive is provided to the first and/or second plurality of filaments, the melt additive may preferably form between about 0.11% to about 20% by weight based on the weight of the first and/or second layers 20, 30. In some forms, the melt additive is more preferably less than about 15% by weight, even more preferably less than about 10% by weight, and most preferably less than about 8% by weight, specifically including any value within these ranges or any range resulting therefrom.

Any suitable hydrophobic melt additive may be utilized. Examples of hydrophobic melt additives include fatty acids and fatty acid derivatives. The fatty acids may be derived from plant sources, animal sources, and/or synthetic sources. Some fatty acids may range from C8 fatty acids to C30 fatty acids; or in the range of C12 fatty acids to C22 fatty acids. In other forms, substantially saturated fatty acids may be used, particularly when saturation occurs as a result of hydrogenation of the fatty acid precursor. Examples of fatty acid derivatives include fatty alcohols, fatty acid esters, and fatty acid amides. Suitable fatty alcohols (R-OH) include those derived from C12-C28 fatty acids.

Suitable fatty acid esters include those derived from: mixtures of C12-C28 fatty acids and short chain (C1-C8, preferably C1-C3) monoalcohols, preferably mixtures of C12-C22 saturated fatty acids and short chain (C1-C8, preferably C1-C3) monoalcohols. The hydrophobic melt additive may include a mixture of mono, di, and/or tri fatty acid esters. One example includes fatty acid esters having glycerin as a main chain, as shown in [1 ].

Wherein Rl, R2, and R3 are each alkyl esters having a number of carbon atoms in the range of 11 to 29. In some forms, the glycerol-derived fatty acid ester has at least one alkyl chain, at least two, or three chains bonded to glycerol, thereby forming a mono-, di-, or triglyceride. Suitable examples of triglycerides include glyceryl tribehenate, glyceryl tristearate, glyceryl tripalmitate, and glyceryl trilinomethyl lysine, and mixtures thereof. In the case of triglycerides and diglycerides, the alkyl chains may be the same length or different lengths. Examples include triglycerides with one alkyl C18 chain and two C16 alkyl chains or two C18 alkyl chains and one C16 chain. Preferred triglycerides include alkyl chains derived from C14-C22 fatty acids.

Suitable fatty acid amides include those derived from mixtures of C12-C28 fatty acids (saturated or unsaturated) and primary or secondary amines. One suitable example of the primary fatty acid amide includes those derived from a fatty acid and ammonia, as shown in [2 ].

Wherein R has a number of carbon atoms ranging from 11 to 27. In at least one other form, the fatty acid can range from a C16 fatty acid to a C22 fatty acid. Some suitable examples include erucamide, oleamide, and bexamide. Other suitable hydrophobic melt additives include hydrophobic silicones. Additional suitable hydrophobic melt additives are disclosed in U.S. patent application serial No. 14/849630 and U.S. patent application serial No. 14/933028. Another suitable hydrophobic melt additive is available from Techmer PM (Clinton, TN) under the trade designation PPM17000 high loading hydrophobicity. One specific example of a hydrophobic melt additive is glycerol tristearate. As used herein, glycerol tristearate is defined as a mixture of long chain triglycerides comprising predominantly C18 and C16 saturated alkyl chain lengths. In addition, varying unsaturation and cis vs trans unsaturated bond configurations may also be present. The alkyl chain length may range from about C10 to about C22. The unsaturation will typically range from 0 to about 3 double bonds per alkyl chain. The ratio of cis to trans unsaturated bond configurations may range from about 1:100 to about 100: 1. Other suitable examples that may be used for the polypropylene and/or polyethylene are triglycerides comprising stearic acid or palmitic acid or both as the fatty acid component, or mixtures of such triglycerides. Other suitable hydrophobic melt additives may include erucamide or polysiloxane.

Any suitable hydrophilic additive may be used. Some suitable examples include those available from Techmer PM (Clinton, TN), which are sold under the following trade names: techmer PPM 15560; TPM12713, PPM19913, PPM 19441, PPM19914, PPM112221 (for polypropylene), PM19668, PM112222 (for polyethylene). Additional examples are available from polyester inc, located in Hammonton, NJ, which is sold under the trade name polyester VW351 PP Wetting Agent (for polypropylene); commercially available from Goulston Technologies inc, located in Monroe, NC, which is sold under the trade name Hydrosorb 1001; and those hydrophilic additives disclosed in U.S. patent application publication 2012/0077886 and U.S. patent 5,969,026 and U.S. patent 4,578,414.

Nucleating agents may be included with the melt additive. Nucleating agents can help drive more or faster blooming of hydrophilic or hydrophobic melt additives. It will therefore produce a characteristic difference in the Z direction, even when the same hydrophobic or hydrophilic melt additive is used for all layers: the nucleating agent, when added to one or less than all of the layers, will produce a more hydrophilic or hydrophobic effect or contact angle effect (depending on the type of additive in those layers) than one or more layers with the same hydrophilic or hydrophobic melt additive but without the nucleating agent. Suitable nucleating agents may include nonitol, triamide, and/or sorbitol-based nucleating agents. Specific but non-limiting examples are: organic nucleating agents such as Millad NX 8000 or (under its new trade name) NX UltraClear GP110B from Milliken company. An example of an effective inorganic nucleating agent is CaCO ₃Or other and especially nanoclays or nanoscale mineral molecules.

For those forms in which the first plurality of filaments comprises a hydrophobic melt additive, the web of material may be incorporated into the disposable absorbent article as a topsheet or, in the case of a tampon, as an overwrap. While conventional wisdom would not generally suggest the use of a hydrophobic topsheet, the web material of the present invention may include apertures that allow for rapid acquisition of liquid insult. In such forms, the hydrophobic topsheet may provide a clean, dry surface against the skin of the wearer. Additionally, the hydrophobic treatment in the first plurality of filaments may also reduce liquid rewet. Examples of webs of materials of the present invention that include hydrophobic and hydrophilic melt additives will be provided in the "examples" section of this specification.

And while common sense may call for enhanced hydrophobicity/hydrophilicity after filament production, such as topical application, application of such compositions may result in additional conflicts. For example, many topically applied treatment agents can migrate to other structures within the absorbent article. Or for the web material of the present invention, the post-production treatment may migrate from the first layer 20 to the second layer 30 or vice versa during application. Such migration may interfere with a desired surface energy difference between the first layer 20 and the second layer 30.

However, a form is envisaged in which the first layer 20 is produced and subsequently treated with a surface energy modifying composition. Subsequently, the second layer 30 is formed onto the first layer 20.

Diameter or cross-sectional area of filament

Another way to create the Z-direction characteristic differences in the web material of the present invention is to utilize different filament sizes in the first plurality of filaments in first layer 20 and the second plurality of filaments in second layer 30. The term "filament size" refers to the cross-sectional dimension, diameter, or area of a filament; for a circular cross-sectional shape, the cross-sectional dimension is a diameter and the area is a circle, but more complex cross-sectional shapes may exist. In addition to or independent of the surface energy differences described above, first layer 20 and second layer 30 may also include filament size differences.

In some forms, the first plurality of filaments may comprise a first size and the second plurality of filaments comprises a second size. The first dimension may be different from the second dimension. In some forms, the first dimension may be greater than the second dimension. The first and second pluralities of filaments may comprise any suitable size. In some forms, the first and second pluralities of filaments may have an average size in a range of about 8 microns to about 40 microns, or a filament denier in a range of 0.5 to 10 denier, specifically including all values in these ranges and any ranges resulting therefrom.

Generally, a nonwoven web with larger filaments will increase permeability. The increase in permeability may provide for faster fluid permeation or transfer or acquisition times, which may be of a desired quality. However, an increase in permeability may unfortunately increase the likelihood of fluid rewet.

In contrast, nonwoven webs with smaller filaments generally have lower permeability but higher capillarity. The lower permeability may mean a slower fluid acquisition time; however, higher capillary action may reduce the likelihood of rewet, which may be desirable.

For those forms of the invention in which the web material 10 is used as a topsheet, a larger filament size in the first layer 20 can mean higher permeability-faster fluid acquisition and lower capillary action. And a smaller filament size in the second layer 30 may mean lower permeability but higher capillarity-reducing the possibility of rewet. Where the web material of the present invention includes an additional layer, the additional layer may also enhance the capillarity/permeability of the web material. For example, the third layer may include a filament size that is smaller than the second layer, and the fourth layer may include a filament size that is smaller than the third layer. Thus, each of the subsequent layers may have increased capillary action. In such forms, a capillary gradient may be configured at locations where capillary action is increased for those layers closer to the absorbent core.

Filament cross-sectional shape

Another way to create Z-direction characteristic differences in the web material of the present invention is to utilize different filament cross-sectional shapes. The first plurality of filaments and/or the second plurality of filaments may comprise any suitable cross-sectional shape. In some forms, the first plurality of filaments may include a shape that is different from a shape of the second plurality of filaments. In other forms, the first plurality of filaments may include a plurality of shapes, at least one of the shapes of the first plurality of filaments being different from the shape of the second plurality of filaments. Similarly, the second plurality of filaments may comprise a plurality of shapes.

The first plurality of filaments and/or the second plurality of filaments may comprise non-round filaments. (circular generally means round and solid, without cavities or hollow sections.) as used herein, the term "non-round filament" describes a filament having a non-round cross-section and includes "shaped filaments" and "capillary channel filaments". Such filaments may be solid or hollow, and they may be trilobal, delta-shaped, and may be filaments having capillary channels on their outer surfaces. The capillary channel can have various cross-sectional shapes, such as "U", "H", "C", and "V". One practical capillary channel Filament is T-401, which is designated 4DG Filament, available from fiber Innovation Technologies (Johnson City, TN). The T-401 filaments are polyethylene terephthalate (PET polyester). Other suitable shapes include circular, circular hollow, or ribbon-shaped.

The cross-sectional shape of the first plurality of filaments and/or the second plurality of filaments may be varied in combination with or independently of the surface energy differences and filament diameter/cross-sectional area differences described above.

Generally, non-round filaments have increased capillary/wicking potential compared to their round filament counterparts due to their higher surface area. In other words, non-round filaments may not readily abandon the fluid disposed thereon. Thus, non-round filaments may not be beneficial for the purpose of masking/rewet in the wearer-facing surface of the web of material. Conversely, non-round filaments may perform much better if disposed below the wearer-facing surface of the absorbent article. In addition, non-round filaments have greater wicking ability, higher capillary suction, and provide more resiliency than their round filament counterparts. If disposed in a layer closer to the absorbent core than a layer comprising a portion of the wearer-facing surface of the absorbent article, each of these attributes may provide more benefits,

in some particular forms, the first layer 20 may include round filaments while the second layer 30 includes non-round filaments. A form of the invention is envisaged in which the first layer 30 and/or the second layer 40 have a mixed filament shape. For example, the first layer 20 may include a higher percentage of round filaments than the second layer 30. And for those forms of the invention that include additional layers, the third layer may include non-round filaments and/or may include a lower percentage of round filaments than the second layer 30. And if provided, the fourth layer may similarly include non-circular filaments and/or may include a lower percentage of circular filaments than the second layer 30.

Additional forms are contemplated wherein the first layer 20 and the second layer 30 each comprise round filaments. The third layer may comprise non-circular filaments. In other forms, the third layer may include round filaments and the fourth layer may include non-round filaments.

Filament cross-sectional configuration

Another way to create Z-direction characteristic differences in a web material of the present invention is to utilize different filament cross-sectional configurations. For example, the filaments of the first layer and/or the second layer may be monocomponent, bicomponent, and/or biconstituent. As used herein, the term "monocomponent" filament refers to a filament formed from one extruder using one or more polymers. This is not meant to exclude filaments formed from one polymer to which small amounts of additives have been added for coloration, antistatic properties, lubrication, hydrophilicity, etc.

As used herein, the term "bicomponent" filament refers to a filament that is extruded from at least two different polymers from separate extruders but spun together to form one filament. Bicomponent filaments are also sometimes referred to as conjugate filaments or multicomponent filaments. The polymers are arranged in substantially constantly positioned distinct zones across the cross-section of the bicomponent filament and extend continuously along the length of the bicomponent filament. For example, the configuration of such bicomponent filaments can be a sheath/core arrangement in which one polymer is surrounded by another; or may be in a side-by-side arrangement, a pie arrangement, or a "sea-island" arrangement. Some suitable examples of bicomponent filament configurations are shown in fig. 3A-3C. For example, the filaments of the web material of the present invention can comprise filaments having a cross-section 300 comprising a first component 300A and a second component 300B arranged in a side-by-side configuration. As shown, the boundary 302 between first component 300A and first component 300B may be readily discernible depending on the composition of first component 300A and second component 300B. In some forms, first component 300A and second component 300B may be present in the filaments in about equal proportions, such as 50/50. However, in some forms, the ratio of first component 300A to second component 300B may vary. Thus, the demarcation 302 can be offset to be more adjacent to one side of the filament. The ratio of the compositions is discussed below.

As another example, a web material of the present invention can include bicomponent filaments having a cross-section 310 comprising a first component 310A and a second component 310B in an eccentric sheath-core configuration. And in the case of this configuration, the core, i.e., second component 310B, may be tangent to the edges of the filaments as shown in fig. 3B, or may be offset from the edges of the filaments. In one specific example of a sheath-core configuration, first component 310A may be concentric with second component 310B.

Another example of a cross-section of a bicomponent filament useful in the present invention is shown in fig. 3C. As shown, filaments having a trilobal cross-section 320 may be utilized. The trilobal cross-section 320 comprises a first component 320A and a second component 320B, wherein the second component 320B is one of the lobes of the trilobal cross-section. As shown, the first component 320A includes about one-third of the filament cross-section 320. In some forms, the border 302 can be displaced, wherein the first composition comprises more or less of the cross-section 320.

Similar configurations are contemplated with all potential filament cross-sections discussed herein. That is, the bicomponent filament cross-section can include the first component and the second component in any of the cross-sectional shapes discussed herein. And in some forms, the multicomponent filaments may be provided with a third component, a fourth component, and the like, depending on the composition used.

The bicomponent filament may comprise two different resins, for example a first resin and a second resin. The resins may have different polymer compositions, melt flow rates, molecular weights, degrees of branching, viscosities, degrees of crystallinity, rates of crystallization, and/or molecular weight distributions. The ratio of the two different polymers may be about 50/50, preferably about 60/40, more preferably about 70/30, or most preferably about 80/20, or any ratio within these ratios. The ratio can be selected to control the amount of curl, strength of the nonwoven layer, softness, bonding, and the like.

As used herein, the term "biconstituent filaments" refers to filaments formed from at least two polymers extruded from the same extruder as a blend. Biconstituent filaments do not have the various polymer components arranged in relatively constantly positioned distinct zones across the cross-sectional area of the filament, and the various polymers are generally not continuous along the entire length of the filament, but rather generally form fibrils which start and end at random. Biconstituent filaments are sometimes referred to as multiconstituent filaments. In one particular example, the bicomponent filament may comprise a multicomponent component.

Additional details regarding bicomponent or multicomponent filaments and methods of making the same can be found in U.S. patent application publication 2009/0104831, published on 4-23/2009; us patent 8,226,625, issued on 7/24/2012; us patent 8,231,595, issued on 7/31/2012; us patent 8,388,594, published on 3/5/2013; and us patent 8,226,626, issued on 7/24/2012.

In some forms, the first plurality of filaments may be monocomponent, while the second plurality of filaments is bicomponent; or vice versa. In some forms, the first plurality of filaments may be bicomponent and the second plurality of filaments multicomponent having at least three components; or vice versa. In other forms, the first plurality of filaments may be monocomponent and the second plurality of filaments are multicomponent having at least three components; or vice versa.

The web materials of the present invention can utilize filament cross-sectional configuration variations, either alone or in combination with the aforementioned surface energy, filament size, and/or filament cross-sectional shape variations. And for those forms that include a third layer and, in some forms, a fourth layer, the filament cross-sectional configuration may not be the same between at least two layers.

Degree of filament crimp

Another way to create Z-direction characteristic differences in the web material of the present invention is to utilize coiled filaments in the first layer 20 and/or the second layer 30. In some forms of the invention, the first layer 20 and/or the second layer 30 may include coiled filaments. For example, the second plurality of continuous filaments may comprise uncrimped-straight filaments, while the first plurality of continuous filaments are crimped. Examples of straight filaments and crimped filaments are shown in fig. 4A and 4B, respectively. In some forms, the first plurality of filaments and the second plurality of filaments may each comprise a coiled filament. In such forms, the first plurality of filaments may include a higher crimp than the second plurality of filaments.

As used herein, "crimped filament" refers to a bicomponent filament that can be configured in a side-by-side, core-over-center sheath, or other suitable configuration. Selection of the appropriate resin combination and bicomponent filament configuration can result in the creation of helical bends or crimps in the filaments. The crimping may occur spontaneously during the spinning or laying process, or may occur spontaneously after the web is formed. In some forms, the nonwoven web may require additional steps (e.g., heat or mechanical deformation) to induce filament crimp. Some exemplary suitable resin combinations for achieving coiled filaments are discussed herein.

It is believed that incorporating coiled filaments into the first layer 20 and/or the second layer 30 may provide advantages over conventional webs of material, particularly when used in the context of disposable absorbent articles. For example, where the first and/or second plurality of filaments are crimped, a higher permeability and/or loft may be achieved as compared to conventional nonwoven webs that do not include crimped filaments. And nonwoven webs comprising crimped filaments are generally perceived by the user as softer.

In addition, webs of material comprising crimped filaments may also facilitate some additional processing. One example includes a mechanical process of manipulating a web of material to create a three-dimensional structure or an open-cell structure. For example, inextensible filament materials may break, stretch, attenuate, or tear when subjected to such mechanical processes. However, if crimped filaments are utilized, the need for extensible filament material is somewhat alleviated. Instead of breaking, stretching, and/or attenuating, the coiled filaments tend to stretch during processing of the coiled filaments. Accordingly, if configured as a coiled filament, a filament material that would otherwise not be suitable for such machining may become suitable. And webs of materials comprising crimped filaments generally exhibit better elastic recovery from machining than webs of other materials. As one particular example, polypropylene and polylactic acid-based filaments are generally not resistant to the mechanical processing required to produce a three-dimensional or porous structure on a nonwoven web; however, when configured as a coiled-filament, such filaments can withstand such machining.

Another benefit of using crimped filaments in a web material relates to tensile elongation. Some web materials utilizing crimped filaments can include better tensile elongation than conventional nonwoven webs. In one particular example, a web of material comprising crimped filaments (including polypropylene/polypropylene bicomponent filaments) can exhibit higher tensile elongation than a conventional nonwoven web comprising filaments (including polypropylene monocomponent filaments).

Yet another benefit of the coiled filaments of the present invention relates to the tensile strength ratio between MD and CD. Webs of the invention utilizing continuous crimped filaments generally exhibit a generally more balanced tensile strength ratio between the MD and CD than that of carded webs of crimped fibrous material. Generally, a crimped fiber carded web material has much higher tensile strength in the MD, because the fibers are typically carded to be aligned in the MD direction.

Yet another benefit of utilizing crimped filaments in the web material of the present invention relates to bond strength. In some forms, especially where the filaments comprise bicomponent polypropylene/polypropylene, better bond strength can be achieved, which means that the material web is more abrasion resistant.

Still further, further benefits of utilizing crimped filaments in the web material of the present invention include compatibility with similar chemical compositions. For example, crimped filaments, which are polypropylene/polypropylene containing bicomponent, can be thermally bonded (bonded) to an underlying material in a polypropylene-based disposable absorbent article. Additionally, the costs associated with polypropylene/polypropylene filaments may be less than the costs associated with other bicomponent filaments. And the polypropylene/polypropylene filaments or filaments comprising two different polyesters may be recyclable relative to bicomponent filaments comprising polyethylene/polypropylene.

The web materials of the present invention may utilize coiled filaments in the first layer 20 and/or the second layer 30 to create Z-direction characteristic differences in the web materials. Coiled filaments may be utilized in the first layer 20 and/or the second layer 30 in combination with or independent of surface energy variations, filament size variations, filament cross-sectional shape variations, and/or filament cross-sectional configurations. And for those forms that include a third layer and, in some forms, a fourth layer, the third layer and/or the fourth layer may include coiled filaments or may include any other filaments described herein.

Layer composition

Another way to create Z-direction characteristic differences in the web material of the present invention is through the use of varying layer compositions. The first and second pluralities of filaments may comprise any suitable composition. Some suitable thermoplastic polymers include polymers that melt and then crystallize or harden upon cooling, but can be remelted upon further heating. Suitable thermoplastic polymers for use herein can have a melting temperature (also referred to as a cure temperature) of from about 60 ℃ to about 300 ℃, from about 80 ℃ to about 250 ℃, or from 100 ℃ to 215 ℃. And the molecular weight of the thermoplastic polymer should be high enough to enable entanglement between polymer molecules and low enough to be melt spinnable.

The thermoplastic polymer may be derived from any suitable material, including renewable resources (including bio-based materials, agricultural materials, and recycled materials), fossil minerals and oils, and/or biodegradable materials. One suitable example of a thermoplastic polymer derived from renewable resources is SHA7260 high density polyethylene from Braskem (philiadelphia, PA).

Other suitable examples of thermoplastic polymers include polyolefins, polyesters, polyamides, copolymers thereof, and combinations thereof. Some exemplary polyolefins include polyethylene or copolymers thereof, including low density polyethylene, high density polyethylene, linear low density polyethylene, or ultra low density polyethylene, such that the polyethylene density is in a range between 0.90 grams per cubic centimeter to 0.97 grams per cubic centimeter, between 0.92 grams per cubic centimeter and 0.95 grams per cubic centimeter, or any value within these ranges or any range within these values. The density of the polyethylene can be determined by the amount and type of branching and depends on the polymerization technique and comonomer type. Polypropylene and/or polypropylene copolymers, including atactic polypropylene; isotactic polypropylene, syndiotactic polypropylene, and combinations thereof, hereinafter referred to as "propylene polymers," may also be used. Polypropylene copolymers, especially ethylene, can be used to lower the melting temperature and improve the properties. These polypropylene polymers can be prepared using metallocene and Ziegler-Natta catalyst systems. These polypropylene and polyethylene compositions can be combined together to optimize end use properties. Polybutylene is also a useful polyolefin, and may be used in some embodiments. Other suitable polymers include polyamides or copolymers thereof, such as nylon 6, nylon 11, nylon 12, nylon 46, nylon 66; polyesters or copolymers thereof, such as maleic anhydride polypropylene copolymers, polyethylene terephthalate; olefin carboxylic acid copolymers such as ethylene/acrylic acid copolymers, ethylene/maleic acid copolymers, ethylene/methacrylic acid copolymers, ethylene/vinyl acetate copolymers, or combinations thereof; polylactic acid; polyacrylates, polymethacrylates, and copolymers thereof such as poly (methyl methacrylate).

Non-limiting examples of suitable commercially available polypropylenes or polypropylene copolymers include Basell Profax PH-835(35 melt flow Rate Ziegler-Natta isotactic polypropylene from Lyondell-Basell); basell metallocene MF-650W (500 melt flow Rate metallocene isotactic polypropylene from Lyondell-Basell); moplen, HP2833, HP462R and S, HP551R, HP552N, HP552R, HP553R, HP561R, HP563S, HP567P, HP568S, RP3231, Polybond 3200(250 melt flow rate maleic anhydride polypropylene copolymer from Crompton); exxon Achieve 3854(25 melt flow rate metallocene isotactic polypropylene from Exxon-Mobil Chemical); mosten NB425(25 melt flow rate Ziegler-Natta isotactic polypropylene from Unipetrol); danimer 27510 (aurohydroxyalkanoate polypropylene from Danimer Scientific LLC); achieve 3155(35 melt flow rate Ziegler-Natta isotactic polypropylene from Exxon Mobil);

the thermoplastic polymer component may be a single polymeric substance, as described above, or a blend of two or more thermoplastic polymers, as described above (e.g., two different polypropylene resins). For example, the constituent filaments of the first layer may comprise polymers such as polypropylene and blends of polypropylene and polyethylene. The web material may comprise filaments selected from the group consisting of polypropylene, polypropylene/polyethylene blends, and polyethylene/polyethylene terephthalate blends. In some forms, the web of material may comprise filaments selected from cellulose, rayon, cotton, other hydrophilic filament materials, or combinations thereof. The filaments may also include a superabsorbent material such as a polyacrylate or any combination of suitable materials.

In some forms, the thermoplastic polymer may be selected from the group consisting of polypropylene, polyethylene, polypropylene copolymers, polyethylene terephthalate, polybutylene terephthalate, polylactic acid, aurohydroxyalkanoates, polyamide-6, and combinations thereof. The polymer may be polypropylene-based, polyethylene-based, aurohydroxyalkanoate-based polymer systems, copolymers and combinations thereof.

Biodegradable thermoplastic polymers are also contemplated for use herein. When in useWhen the biodegradable material is buried underground or otherwise exposed to microorganisms (including exposure to environmental conditions conducive to the growth of microorganisms), the biodegradable material is susceptible to digestion by microorganisms such as molds, fungi, and bacteria. Suitable biodegradable polymers also include those biodegradable materials that are environmentally degradable using aerobic or anaerobic decomposition methods or due to exposure to environmental elements such as sunlight, rain, moisture, wind, temperature, and the like. Biodegradable thermoplastic polymers may be used alone or in combinations of biodegradable or non-biodegradable polymers. Biodegradable polymers include polyesters that include aliphatic components. Wherein the polyester is an ester polycondensate comprising an aliphatic component and a poly (hydroxy carboxylic acid). Ester polycondensates include dicarboxylic acid/diol aliphatic polyesters such as polybutylene succinate, polybutylene succinate-co-adipate, aliphatic/aromatic polyesters such as terpolymers made from butanediol, adipic acid and terephthalic acid. Poly (hydroxy carboxylic acids) include lactic acid based homopolymers and copolymers, Polyhydroxybutyrate (PHB), or other polyhydroxyalkanoate homopolymers and copolymers. Such gold hydroxyalkanoates include PHB with higher chain length monomers such as C ₆-C₁₂And copolymers of higher chain length monomers such as those polyhydroxyalkanoates disclosed in U.S. Pat. nos. RE 36,548 and 5,990,271.

An example of a suitable commercially available polylactic acid is from Cargill Dow^TMNATUREWORKS sold under trade names 6202D, 6100D, 6252D, and 6752D; and 6302D and LACEA from Mitsui Chemical. One example of a suitable commercially available diacid/diol aliphatic polyester is the polybutylene succinate/adipate copolymer sold under the tradenames BIONOLLE 1000 and BIONOLLE 3000 from Showa High Polymer Company, Ltd. (tokyo, japan). One example of a suitable commercially available aliphatic/aromatic Copolyester is poly (tetramethylene adipate-co-terephthalate) sold under the trade name EASTAR BIO Copolyester from Eastman Chemical or ECOFLEX from BASF.

The polypropylene may have a melt flow index greater than 5g/10min as measured by ASTM D-1238 for polypropylene. Other contemplated polypropylene melt flow indices include greater than 10g/10min, greater than 20g/10min, or from about 5g/10min to about 50g/10 min.

In some forms, the first plurality of filaments and/or the second plurality of filaments may comprise elastomeric filaments. The elastic or elastomeric filaments may be stretched at least about 50% of their original dimension and may recover to within 10% of their original dimension. In some forms, the first plurality of filaments may comprise a polymer such as polypropylene and a blend of polypropylene and polyethylene. In some embodiments, the second plurality of filaments may comprise a polymer such as polypropylene, polypropylene/polyethylene blends, and polyethylene/polyethylene terephthalate blends. Some suitable examples of elastomers suitable for use in producing filaments are made by Exxon ^TMUnder the trade name Vistamaxx^TM2330. 6202 and 7050; from Kraton^TMSold under the tradenames G1643, MD6705, DM 1648; from BASF^TMUnder the trade name Elastollan^TMB95A 11N000, 2280A, EB 60D 11; and from Dow^TMUnder the trade name Infuse^TM9817 and 9900.

Some specific examples of compositions of crimped filaments that can be used in webs of material of the present invention include polyethylene/polypropylene side-by-side bicomponent filaments. Another example is a polypropylene/polyethylene bicomponent filament, wherein the polyethylene is configured as a sheath and the polypropylene is configured as a core within the sheath. Another example is a polypropylene/polypropylene bicomponent filament, wherein two different propylene polymers are configured in a side-by-side configuration. Another example is a polypropylene/polylactic acid bicomponent filament. Another example is a polyethylene/polylactic acid bicomponent filament. In the case of polyethylene/polylactic acid bicomponent filaments, such filaments may be produced from renewable resources. For example, both the polyethylene and polylactic acid may be of biological origin.

In some forms, the composition of the first plurality of filaments may be different from the composition of the second plurality of filaments. For those forms that include additional layers, such as a third layer and a fourth layer, the additional layers may include the composition of the first layer 20 or the second layer 30. However, in some forms, the third and fourth layers may comprise a different filament composition than the first and/or second layers.

A form of the invention is envisaged in which the first plurality of filaments and/or the second plurality of filaments comprise an agent in addition to their constituent chemical substances. For example, suitable additives include those used in: coloring, antistatic properties, coefficient of friction, lubrication, hydrophilicity, and the like, and combinations thereof. These additives, such as titanium dioxide for coloration, are generally present in an amount less than about 5 weight percent, and more typically about 2 weight percent.

In one particular example, the first plurality of filaments may comprise a constituent chemical that provides a first color to the first layer 20, while the second plurality of filaments may comprise a constituent chemical that provides a second color to the second layer 30. The first color and the second color may be different. Such color differences may be beneficial in providing a masking benefit against liquid insults in the absorbent article.

For those forms of the invention in which one of the first or second layers 20, 30 comprises a film, any suitable material may be utilized. Some suitable examples are described in the following patents: U.S. Pat. No. 3,929,135 to Thompson, entitled "Absorptive Structures Having stressed pipes Capillaries", at 30.12.1975; U.S. Pat. No. 4,324,246 entitled "Disposable Absorbent Article Having A Stain Resistant Topsheet" issued to Mullane and Smith at 13.4.1982; U.S. Pat. No. 4,342,314 entitled "Resilient Plastic Web exclusion Fiber-Like Properties" issued to Radel and Thompson at 3.8.1982; and U.S. Pat. No. 4,463,045 entitled "macromolecular Expanded Three-Dimensional Plastic Web expanding Non-gloss visual Surface and close-Like Table expression" issued to Ahr, Lewis, Mullane, and Ouelette on 31/7/1984. Additional exemplary films are discussed in U.S. patent 7,410,683; 8,440,286 and 8,697,218.

The web materials of the present invention can utilize layer composition modification, either alone or in combination with the aforementioned surface energy, filament size, filament cross-sectional shape, filament cross-sectional configuration, and/or coiled-filament modification. And for those forms that include a third layer and, in some forms, a fourth layer, the filament composition may not be the same between at least two layers.

Softness/coefficient of friction reduction

As previously mentioned, the web material of the present invention may comprise a plurality of nonwoven layers. The addition of melt additives to the thermoplastic polymers listed herein can provide Z-direction characteristic differences related to softness of one or more of the layers. For example, the first plurality of filaments of the first layer 20 may include a melt additive that reduces the coefficient of friction of the filaments, which may result in a greater perception of softness by a user. The second plurality of filaments of the second layer 30 may not comprise the same melt additive, or may not comprise a melt additive with respect to reducing the coefficient of friction between the second plurality of filaments.

The melt additive provided for softness is preferably a fast body slip agent and may be a hydrocarbon having one or more functional groups selected from hydroxides, aryl and substituted aryl groups, halogens, alkoxy groups, carboxylates, esters, carbon unsaturates, acrylates, oxygen, nitrogen, carboxyl, sulfate and phosphate. In one particular form, the slip agent is a salt derivative of an aromatic or aliphatic hydrocarbon oil, notably a metal salt of a fatty acid, including carboxylic, sulfuric, and phosphoric aliphatic saturated or unsaturated acid metal salts having a chain length of 7 to 26 carbon atoms, preferably 10 to 22 carbon atoms. Examples of suitable fatty acids include monocarboxylic acids, lauric acid, stearic acid, succinic acid, stearoyl lactic acid, phthalic acid, benzoic acid, hydroxystearic acid, ricinoleic acid, naphthenic acid, oleic acid, palmitic acid, erucic acid, and the like, as well as the corresponding sulfuric and phosphoric acids. Suitable metals include Li, Na, Mg, Ca, Sr, Ba, Zn, Cd, Al, Sn, Pb, and the like. Representative salts include, for example, magnesium stearate, calcium stearate, sodium stearate, zinc stearate, calcium oleate, zinc oleate, magnesium oleate, and the like, as well as the corresponding higher metal alkyl sulfates and metal esters of higher alkyl phosphoric acids.

In other forms, the slip agent is a non-ionically functionalized compound. Suitable functionalized compounds include: (a) esters, amides, alcohols and acids of oils, including aromatic or aliphatic hydrocarbon oils, e.g., mineral oils, naphthenic oils, paraffinic oils; natural oils such as castor oil, corn oil, cottonseed oil, olive oil, rapeseed oil, soybean oil, sunflower oil, other vegetable oils, and animal oils, among others. Representative functionalized derivatives of these oils include, for example, polyol esters of monocarboxylic acids such as glycerol monostearate, pentaerythritol monooleate, and the like, saturated and unsaturated fatty acid amides or ethylene bis (amides), such as oleamide, erucamide, linseed oil amide, and mixtures thereof, sugar alcohols, polyether polyols such as polyethylene glycol, and adipic acid, zelaic acid, and the like; (b) waxes such as carnauba wax, microcrystalline wax, polyolefin waxes, e.g., polyethylene wax; (c) fluoropolymers such as polytetrafluoroethylene, fluoro-oils, fluoro-waxes, and the like; and (d) silicon compounds such as silanes and siloxane polymers including silicone oils, polydimethylsiloxanes, amino-modified polydimethylsiloxanes, and the like.

The fatty amides useful in the present invention are represented by the formula:

RC(O)NHR¹

Wherein R is a saturated or unsaturated alkyl group having 7 to 26 carbon atoms, preferably 10 to 22 carbon atoms, and R¹Is independently hydrogen or a saturated or unsaturated alkyl group having from 7 to 26 carbon atoms, preferably from 10 to 22 carbon atoms. Compounds according to this structure include, for example, palmitamide, stearamide, arachidate, phenylacetamide, oleamide, erucamide, linoleamide, octadecanetearylamide, palmityl palmitamide, octadecanoarachidonic acid, and mixtures thereof.

The ethylene bis (amides) useful in the present invention are represented by the formula:

RC(O)NHCH₂CH₂NHC(O)R

wherein each R is independently a saturated or unsaturated alkyl group having from 7 to 26 carbon atoms, preferably from 10 to 22 carbon atoms. Compounds according to this structure include, for example, stearyl ethyl stearamide, stearyl ethyl palmitamide, palmitamide ethyl stearamide, ethylene distearamide, ethylene dioleamide, octadecane erucamide, erucamide ethyl erucamide, ethyl oleamide, erucamide ethyl oleamide, stearyl ethyl erucamide, erucamide ethyl palmitamide, palmitamide ethyl oleamide, and mixtures thereof.

Commercially available examples of fatty amides include Ampacet 10061, which comprises a 50:50 mixture of 5% primary amides of erucic and stearic acids and polyethylene; elvax 3170, which comprises a similar blend of amides of erucic and stearic acids in a blend of 18% vinyl acetate resin and 82% polyethylene. These slip agents are available from DuPont. Slip agents are also available from Croda Universal and include Crodamide OR (an oleamide), Crodamide SR (stearamide), Crodamide ER (an erucamide), and Crodamide BR (a phenylacetamide); and are available from Crompton and include Kemamide S (stearamide), Kemamide B (phenylacetamide), Kemamide O (an oleamide), Kemamide E (an erucamide), and Kemamide (an N, N' -ethylene bis stearamide). Other commercially available slip agents include erucamide ER erucamide.

Other suitable melt additives for softness/reduced coefficient of friction include erucamide, stearamide, oleamide, and silicones such as polydimethylsiloxane. Some specific examples include from Croda^TMCrodamide of (1)^TMSlip and antiblock agents, and from Ampacet^TMSlip BOPP. Some additional specific examples of softness increasing/friction coefficient reducing melt additives particularly suitable for polypropylene come from Techmer ^TMAnd are sold under the tradenames PPM16368, PPM16141, PPM11790, PPM15710, PPM111767, PPM111771, and PPM 12484. Some specific examples, particularly applicable to polyethylene, are from Techmer^TMAnd are sold under the trade names PM111765, PM111770, and PM 111768.

The web materials of the present invention may utilize softness melt additive variations, either alone or in combination with the aforementioned surface energy, filament size, filament cross-sectional shape, filament cross-sectional configuration, and/or coiled-filament variations. And for those forms that include a third layer and, in some forms, a fourth layer, the filament composition may not be the same between at least two layers.

Additionally, some softness melt additives can provide softness benefits as well as surface energy modification benefits. For example, fatty amides also provide hydrophobic benefits. These melt additives are listed herein under hydrophobic melt additives.

Thickness of

Another way to create Z-direction characteristic differences in the web material of the present invention is via a change in the thickness of the first layer 20 relative to the thickness of the second layer 30. For example, the first plurality of filaments may comprise crimped filaments, as previously discussed. In such forms, it may be beneficial to create a first layer 20 having a thickness greater than the thickness of a second layer 30 so that liquid insult may be better masked due to the increased distance from the first surface 50 of the web of material. The thickness of each layer and the overall material web can be adjusted by varying at least one of the basis weight of the layers, the filament size, the filament shape, the filament crimp, or by any other suitable process. In other forms, the second layer 30 may have a thickness greater than the thickness of the first layer 20. Methods of measuring thickness are provided below.

In some forms, the thickness of the layer may not be readily discernable without extensive analysis. For example, if the difference between the first layer 20 and the second layer 30 is related only to surface energy, visual analysis may not be sufficient to determine the boundary 54 between the first layer 20 and the second layer 30. However, for other forms, for example, where the differences relate to filament cross-sectional shape, filament size, filament cross-sectional configuration, and/or crimped filaments, visual inspection-as herein-may provide the thickness of the first layer 20/second layer 30. In principle, we can vary the thickness by varying the number of filaments (basis weight of one of the layers) or by varying the porosity (i.e. void volume fraction).

For those forms of the invention that include a third layer, the third layer may include a thickness that is different than the thickness of first layer 20 and/or the thickness of second layer 30.

Permeability, capillary action, collection, rewet

Each of the foregoing layer characteristics may affect the properties of their respective layers, such as permeability, porosity, capillarity, acquisition, rewet, softness, masking, and/or visual differences such as color differences. Many of these characteristics present a compromise problem. For example, the rapid acquisition time of liquid insult can lead to potential rewet problems. These trade-off issues are discussed in more detail in the "examples" section of this specification.

Web of material-MD and/or CD characteristic differences

In addition to the Z-direction characteristic differences across layers that can be created by modifying the layers, such as surface energy, filament size, filament cross-sectional shape, filament cross-sectional configuration, filament crimp, filament composition, softness/coefficient of friction reduction, and/or thickness of the layers, the web material 10 of the present invention can additionally include intentional MD/CD characteristic differences within each layer. The MD/CD characteristic differences discussed below may be utilized in conjunction with or independently of the aforementioned Z-direction characteristic differences. The use of MD/CD characteristic differences may similarly affect the properties of the web material, such as permeability, softness, acquisition, rewet, masking, and/or visual differences such as color differences.

The MD/CD characteristic differences may be created by creating discrete discontinuities in the web material of the present invention. These discrete discontinuities may change the properties in localized areas of each of the layers. For example, the first surface 50 and the second surface 52 of the web material 10 of the present invention are generally considered to be planar. The discontinuity is an interruption of the planar surface-first surface 50 and/or second surface 52. Some exemplary discontinuities include holes, bond sites, embossments, tunnel clusters, packed clusters, nested clusters, corrugations, and/or grooves.

Hole(s)

Referring to fig. 5A and 5B, one way to create MD and/or CD feature differences is by using holes. A laminate 100 is shown comprising a web of material 10 and a layer of material 170, such as a secondary topsheet or acquisition layer. In one example, the web material 10 of the present invention can further include apertures 125 extending from the first surface 50 to the second surface 52 of the web material 10. As shown, the web material 10 can include a plurality of apertures 125. And as shown, apertures 125, although extending through web material 10, may not extend through layer of material 170. The material layer 170 may be any suitable layer from a disposable absorbent article, such as a secondary topsheet, an acquisition layer, a distribution layer, combinations thereof, and the like.

In another form, material layer 170 may be an additional layer integrally formed with web material 10 in which apertures 125 have been created with an ablation process, such as a laser-based material removal step that precisely removes small areas of filament material (in an intentional pattern) to a depth such as one or two layers. Forms of the invention are envisaged in which the holes extend through the first layer 20 only via an ablation process and not through the second layer 30; or vice versa. For example, discrete portions of the first layer 20 may be ablated to form holes therethrough. And wherein the second layer comprises a color difference from a color of the second layer that would be more readily visible through the discrete portions. The second color will appear as a different color, albeit outside of the discrete portion.

The apertures 125 can increase the permeability of the web material 10 and also reduce acquisition time. The apertures 125 may be any suitable size. For example, the holes 125 may have a diameter of about 0.1mm²To about 15mm²Preferably about 0.3mm²To about 10mm²More preferably about 0.5mm²To about 8mm²Or most preferably about 1.0mm²To about 5mm²"effective aperture area" within the range specifically includes all 0.05mm within the specified range and all ranges formed therein or thereby²And (4) increasing. All "effective pore areas" are determined using the "pore test" described herein. "effective pore area" is discussed in more detail in U.S. patent applicationSequence 14/933,028; 14/933,017, respectively; and 14/933,001.

The holes 125 may be created by any suitable method. For example, in some forms, each of the holes 125 may be at least partially surrounded by a fused lip 135. In some forms of the invention, the first and second layers 20, 30 may be joined around the perimeter of each of the plurality of holes 125 via a fused lip 135. For example, the melting lip 135 may be created in part by melting/fusing filaments of the first and second layers 20, 30. During melting/fusing, the molten filament material may form bonds with the filaments around first layer 20 and second layer 30, thereby forming film-like regions.

The film-like section can then be broken. The splitting of the film-like section forms the aperture 125 and the melt lip 135. Generally, the web material 10 is stretched in the CD direction in order to rupture the melted regions. This stretching causes a portion of the film-like section to split and form the aperture 125. The remainder of the film-like region remains unbroken, forming a molten lip 135. Additionally, during the aperturing process, the web material 10 is generally under tension in the MD direction. This process is also described in U.S. Pat. nos. 5,658,639; 5,628,097; 5,916,661; 7,917,985, respectively; and U.S. patent application publication 2003/0021951 and U.S. patent application serial No. 14/933,028; 14/933,017, respectively; and 14/933,001. Additional processes for aperturing a web of material are described in U.S. patents 8,679,391 and 8,158,043, and U.S. patent application publications 2001/0024940 and 2012/0282436. Other methods for aperturing a web of material are provided in U.S. patent 3,566,726; 4,634,440, respectively; and 4,780,352.

For those forms of the invention that include a third layer and optionally a fourth layer, apertures 125 can be formed in the resulting web material. In such forms, the apertures may extend from the first surface through the second surface of the resulting web material.

Forms of the invention are envisaged in which the material web of the invention is provided with apertures in a pattern or a plurality of patterns. For example, a web material of the present invention may be provided with a series of apertures. Some exemplary patterns are disclosed in relation to fig. 19-32.

Referring to fig. 19-32, a web of material 1000 of the present invention can comprise a series of apertures comprising a plurality of patterns 1110A and 1110B with continuous or semi-continuous land areas. As shown, the first pattern 1110A can include a first plurality of apertures oriented in a direction substantially parallel to the machine direction 1675, and a second plurality of apertures oriented at a plurality of angles with respect to the machine direction. Similarly, the second pattern 1110B can include a third plurality of apertures oriented at a plurality of angles with respect to the machine direction 1675, and a fourth plurality of apertures that are substantially parallel to the machine direction 1675. As shown, the apertures of the first pattern 1110A and/or the second pattern 1110B may have different lengths, different angles relative to the machine direction 1675, and/or different "effective aperture areas. The "effective aperture area" is discussed below.

Additionally, at least one or more apertures in the first pattern 1110A can be substantially enclosed by the second pattern 1110B, e.g., the third and fourth plurality of apertures. For example, the second pattern may form a quilted-like pattern, such as a diamond-shaped border or any other suitable shape, wherein the first pattern is disposed within the second pattern to form a cell. The combination of the first pattern and the second pattern may be repeated so that there are a plurality of cells. In addition, the first pattern within the second pattern may be different from one cell to the next. Additional patterns may be used. It is believed that the angling of the apertures relative to the machine direction 1675 aids in fluid acquisition/distribution. For example, fluid moving in the machine direction 1675 along the patterned web 1164 may be diverted due, in part, to the angled apertures.

Still referring to fig. 18-32, as previously described, the first pattern 1110A and/or the second pattern 1110B can include a plurality of apertures, at least a portion of which are at a first angle 1680 relative to the machine direction 1675 and another portion of which are at a second angle 1682 relative to the machine direction. The first angle 1680 and the second angle 1682 may be different from one another. In some forms, the second angle 1682 can be a mirror image of the first angle 1680. For example, the first angle may be about 30 degrees from an axis parallel to the machine direction 1675, while the second angle is-30 degrees from the axis parallel to the machine direction 1675. Similarly, the first pattern 1110A and/or the second pattern 1110B can comprise a plurality of apertures oriented substantially parallel to the machine direction 1675. Apertures oriented generally parallel to the machine direction 1675 generally have a lower aspect ratio (described below) and a greater "effective aperture area" (described below), as opposed to those apertures that are angled relative to the machine direction 1675. It is believed that those apertures with increased "effective aperture area" allow for faster fluid acquisition times. Although any suitable angle may be utilized, as discussed below, once first angle 1680 and second angle 1682 increase from machine direction 1675 by more than 45 degrees (45 degrees in the case of second angle 1682), the force of the cross direction 1677 stretch will act more along the long axis of the hole than perpendicular to the long axis. Thus, apertures that are angled more than 45 degrees (45 degrees in the case of the second angle 1682) relative to the machine direction 1675 typically include a smaller "effective aperture area" than those apertures that are angled to a lesser degree relative to the machine direction 1675.

As previously mentioned, it is believed that the angled apertures provide additional fluid handling benefits to the patterned web 1164. In some forms, greater than about 10% of the pores are angled with respect to the machine direction 1675. Additional forms are contemplated wherein greater than about 20%, greater than about 30%, greater than about 40%, greater than about 50%, greater than about 60%, greater than about 70%, greater than about 80%, and/or less than 100%, less than about 95%, less than about 90%, less than about 85% of the pores are angled with respect to the machine direction 1675, including any number or any range encompassed by the foregoing values.

Referring to fig. 19-32, the closer to the centerline 1690 of the web material 1000, the greater the cluster density of the apertures may be. For example, the inter-hole distance between adjacent holes closer to centerline 1690 may be a first distance, while the inter-hole distance between adjacent holes further from centerline 1690 may be a second distance. The first distance may be less than the second distance. For example, the inter-hole distance between adjacent holes may be about 1 mm. Thus, the first distance may be about 1mm, while the second distance may be about 5mm or greater. Additional forms are contemplated in which the inter-hole distance between adjacent holes increases with increasing distance from the centerline. The interpore distance is also discussed below.

Additionally, in some cases, holes closer to centerline 1690 may be angled at a first angle 1680, while holes further from centerline 1690 are positioned at a second angle 1682. Relative to centerline 1690, first angle 1680 may be greater than second angle 1682. For example, holes further from centerline 1690 may be oriented such that they are generally parallel to centerline 1690, while holes positioned closer to centerline 1690 are angled with respect to centerline 1690. In some forms, the angle at which the holes are positioned relative to centerline 1690 may decrease as the distance from centerline 1690 increases. For example, a first hole adjacent to centerline 1690 may be oriented at a first angle of 30 degrees with respect to centerline 1690, while a second hole 1mm from centerline 1690 may be oriented at 20 degrees from the centerline. The aperture positioned furthest from centerline 1690 may be generally parallel to centerline 1690. Additional configurations are contemplated in which holes near centerline 1690 are angled to a lesser degree than those holes further from centerline 1690. In some embodiments, holes near centerline 1690 may be substantially parallel to centerline 1690, while holes further from centerline 1690 are angled with respect to centerline 1690. The Ferrett angle of the holes is also discussed below.

As previously mentioned, the length of the holes may also vary. Together with or independent of the angling as disclosed above, in some embodiments, the holes adjacent to centerline 1690 may be longer than those further from centerline 1690. Similarly, the size of the holes may vary. Variation of the aperture size (effective aperture area) may be used in combination with or independently of variation of the aperture angle and/or variation of the aperture length. For those forms in which the aperture size may vary, larger apertures may be positioned adjacent centerline 1690, while apertures having smaller "effective aperture area" are positioned further from centerline 1690. For example, apertures adjacent to centerline 1690 may have an effective aperture area of 15 square millimeters, while apertures further from the centerline may have a smaller effective aperture area, such as 1.0 square millimeters. Any of the values/ranges of effective pore area provided herein can be used to construct the effective pore area variance described above.

As previously mentioned, the angle of orientation of the apertures can affect the fluid handling capability of the web material 1000. In addition, the length of the holes, the width of the holes, "effective hole area," spacing between holes, and hole density may similarly affect fluid handling. However, many of the length of the holes, width of the holes, angle of orientation, spacing, and density can have competing/detrimental effects on other variables. As previously described, apertures that are angled more than the machine direction 1675 tend to be smaller in opening and therefore have a smaller effective aperture area than apertures that are parallel to the machine direction 1675 or are angled less relative to the machine direction 1675. Similarly, angled holes that are too closely spaced together tend to be smaller in opening and thus have a smaller effective hole area. Thus, the inter-hole distance between adjacent angled holes may increase beyond the inter-hole distance between holes oriented substantially parallel to the machine direction 1675. Additional details of such forms are also discussed in U.S. patent application serial No. 14/933,028; 14/933,017, respectively; and 14/933,001.

Additional processes for forming apertures in the web material of the present invention are contemplated. Some additional processes for forming the holes are disclosed in U.S. patents 8,679,391 and 8,158,043, and U.S. patent application publications 2001/0024940 and 2012/0282436. Other methods for aperturing a web are provided in U.S. patent 3,566,726; 4,634,440, respectively; and 4,780,352.

Referring again to fig. 5A and 5B, the web material 10 of the present invention can include apertures (including patterned apertures) as described above, along with the aforementioned Z-direction feature differences. Or the apertures described herein may be used independently thereof. Generally, the pores increase permeability. However, introducing apertures in the topsheet may also increase the likelihood of rewet.

As previously mentioned, forms of the invention are contemplated in which the holes extend through the first layer 20 but not through the second layer 30; or vice versa. Such a web of material may be obtained, for example, by forming the first layer 20 and forming apertures therein. Subsequently, a second layer 30 may be formed on the first layer 20, as described herein; or vice versa.

Bonding site

Yet another way to create MD and/or CD characteristic differences in the web material 10 is through the use of bond sites. Referring now to fig. 5A, 5C, and 5D, the web material 10 may further include a plurality of bond sites 175. Adhesive sites 175 may join first layer 20, second layer 30, and material layer 171. The material layer 171 can be a secondary topsheet or a distribution layer, wherein the web material 10 forms part of the topsheet of the absorbent article.

In some forms, bond sites 175 may be formed when: the web material 10 and the material layer 171, such as a secondary topsheet or acquisition layer, are passed through a nip between a pair of counter-rotating rollers that apply a large amount of pressure such that the filament material is deformed into a flat topography and typically causes the filaments in these bond sites to attach to each other. At least one of the rollers includes nubs that compress the web material 10 at the bond sites 175. In some forms of the invention, the nubs can engage the first surface 50 of the first layer 20 and compress the web material 10 and the material layer 171. The compression may occur in the negative Z direction and may generally thin the material of the first layer 20, the second layer 30, and the material layer 171, which constitutes the bond sites 175. This compression may, in some forms, be combined with the application of heat, which may cause the constituent materials of first layer 20, second layer 30, and material layer 171 to fuse together at bond sites 175.

Referring to fig. 5D, there may be alternative forms of bond sites 175. Recall that the bond formation may originate from a pair of rollers, one of which includes a protrusion. A form of the invention is contemplated wherein each of the pair of rollers includes nubs and as the nubs engage the material web 10 and the material layer 171, a first nub from a first roller can compress the material web 10 and the material layer 171 in the negative Z-direction and a second nub from a second roller can compress the material web 10 and the material layer 171 in the positive Z-direction. In such forms of the invention, the resulting bond sites 175 can have indentations on the first surface 50 of the web of material 10 and the second surface 55 of the laminate 100. And for those forms in which there is an additional layer that has been subjected to a bonding process, the constituent materials of the additional layer are intimately connected and adhered to the constituent materials of the first and second layers 20, 30 and material layer 171. The bonding of the component materials of first layer 20, second layer 30, material layer 171, and the additional layers may produce film-like sections on opposite sides of laminate 100.

Bond sites 175 of the present invention may be of any suitable shape, essentially any geometric 2-dimensional shape that may be drawn. Some suitable shapes include circular, oval, rectangular, diamond, heart, star, clover (3 leaves, 4 leaves), bowtie, and combinations thereof. In some forms, the bond sites 175 can include a variety of shapes. Suitable bond shapes are discussed in U.S. patent application serial No. 14/933,017.

The bond sites 175 can affect the softness of the web material 10 as well as its resiliency. For example, a soft feel may be achieved if adjacent bond sites 175 are spaced apart (center-to-center) by more than 4mm or between about 10mm to about 12 mm. Conversely, if the center-to-center spacing is less than about 4mm, the adjacent bond sites 175 may not provide a soft feel. Such spacing and the difference between "soft" and "not soft" also depends on the bond shape or combination of shapes. The bond sites 175 may be used in conjunction with or separate from the holes 125. Processes for making bonds are well known in the art and include thermal bonding and high pressure bonding. In addition, forms of the invention are also envisaged in which the bond sites are provided in a pattern. Details of such forms are discussed in more detail in U.S. patent application serial No. 14/933,028; 14/933,017, respectively; and 14/933,001.

The layers of the present invention may be bonded together via primary bond sites. Typically, the primary bond sites are thermal point bonds that fuse or compress all of the layers of the web material together in discrete areas to form film-like discrete primary bond sites. The bond sites 175 discussed herein do not include primary bond sites.

The web material 10 of the present invention can include bond sites 175 (including patterned bond sites) as described above, along with the aforementioned Z-direction characteristic differences and/or apertures. Or the apertures described herein may be applied independently thereof. In one particular example where the first layer 20 includes a first color and the second layer 30 includes a second color different from the first color, the bond sites 175 may effectively shift the second color seen through the bond sites 175 such that the second color seen through the first layer 20 is different from the color seen via the bond sites 175. The same effect may be achieved if the first and second layers 20, 30 comprise the same color but the material layer 171 comprises a color different from the color of the first and second layers 20, 30. Such color effects are disclosed in more detail in U.S. patent application serial No. 14/933,001.

Embossing part

Another way to create MD and/or CD characteristic differences in the web material 10 of the present invention is through the use of embossing sections. Referring to fig. 5E, unlike the bond sites 175 (shown in fig. 5A, 5C, and 5D), the embossed portion 180 typically does not result in actual bonding of the component materials of the first layer 20, the second layer 30, and the material layer 170, e.g., the second topsheet or acquisition layer, via melting. In contrast, the embossed portion 180 tends to visibly and permanently compress the first layer 20, the second layer 30, and the material layer 170. For those forms of the invention that include additional layers, the embossment 180 can include a first layer 20, a second layer 30, a material layer 170, and additional layers. In some forms, the embossing section 180 may be limited to only the web material 10 or additional layers (if present).

The embossed portion 180 may provide an acquisition gradient in the absorbent article. For example, if the web material 10 forms a portion of a topsheet of an absorbent article, the embossed portion 180 may not readily receive liquid insult. In contrast, the embossments 180 may act as fluid highways that can distribute insults to various regions of the absorbent core in the absorbent article.

The embossments 180 may be used in conjunction with the apertures 125, bond sites 175, and/or any of the Z-direction feature differences disclosed herein, or may be utilized independently thereof. Generally, the embossed portions will reduce permeability in the embossed areas, but also reduce the likelihood of rewet in the absorbent article.

Forms of the invention are contemplated in which either the first layer 20 or the second layer 30 is embossed prior to forming the second layer 30 or the first layer 20 formed thereon, respectively. Forms are also envisaged in which the material web comprises at least a third layer in addition to the first 20 and second 30 layers. In such forms, the first and second layers may be embossed prior to forming the third layer thereon.

Tunnel cluster

Another way to create feature differences in MD and/or CD is via the use of tunnel clusters. Referring to fig. 6A, a web of material of the present invention can include a tunnel bank 270. As shown, in some forms, some of the second plurality of filaments of second object layer 30 may extend beyond first surface 50 in the positive Z-direction to form tunnel clusters 270. And corresponding openings 285 may be created in the second surface 52 of the web material 10.

The tunnel cluster 270 may occur when: localized areas of the constituent materials of the first and second layers 20, 30 are urged in the positive Z-direction so that the material of the first and/or second layers 20, 30 may be disposed above the first surface 50 of the web material 10. The arrangement of the second plurality of filaments of the second layer 30 may form a tunnel tuft 270. And as shown in fig. 6A, in some forms the placement of the first plurality of filaments in the first layer 20 can cause at least some of the first plurality of filaments to break under extrusion in the Z-direction. In such forms, the tunnel tuft 270 may extend through the ends 245 of the first plurality of filaments. However, as shown in fig. 6B, the arrangement of the first plurality of filaments of the first layer 20 can produce an outer tuft 230. In some forms, the outer cluster 230 may form a roof over the tunnel cluster 270.

In some forms, the web of material 10 of the present invention can include a plurality of tunnel clusters 270 without a corresponding outer cluster 230, and/or similarly can include a plurality of tunnel clusters 270 each disposed within a corresponding outer cluster 230.

Additional permutations of tunnel clusters are provided in relation to fig. 6C-6D. As shown, the tunnel clusters 270 and/or the outer clusters 230 can extend beyond the second surface 52 of the web material 10. However, the pushing of the material of the first and second layers 20, 30 may be performed in the negative Z-direction as opposed to being pushed in the positive Z-direction. And similar to fig. 6A, some of the second plurality of filaments of the second object layer 30 may break, as shown in fig. 6C; or an outer cluster 230 may be formed as shown in fig. 6D.

Fig. 6A-6E illustrate tunnel tufts 270 that may be formed from a web of material that includes extensible filaments. The tunnel tufts 270 and the outer tufts 230 disclosed herein comprise a plurality of endless filaments that are substantially aligned such that each of the tunnel tufts 270 and the outer tufts 230 has a different linear orientation and the longitudinal axis L of the tufts, e.g., 270, 230. By "aligned" it is meant that the looped filaments are substantially all oriented such that, if viewed in plan view, each of the looped filaments has a significant vector component parallel to the transverse axis, and may have a major vector component parallel to the transverse axis. The transverse axis T is substantially orthogonal to the longitudinal axis in the MD-CD plane and the longitudinal axis is substantially parallel to the MD.

Another feature of the tunnel tufts 270 and the outer tufts 230 shown in fig. 6A-6E, which are formed from extensible, non-crimped filaments, can be their generally open structure characterized by open void regions 633 defined within the interior of the tunnel tufts 270. The term "void region" is not intended to refer to a region completely free of any filaments. Void region 633 of tunnel cluster 270 may include a first void space opening and a second void space opening. Rather, the term is intended to be a general description of the general appearance of the tunnel cluster 270. Thus, in some tunnel clusters 270, an acyclic filament or a plurality of loose acyclic filaments may be present in void region 633. By "open" void region, it is meant that both longitudinal ends of the tunnel cluster 270 are substantially open and free of filaments, such that the tunnel cluster 270 can form a structure like a "tunnel" structure in an uncompressed state, as shown in fig. 6A-6D.

Referring to fig. 6E, the tunnel tufts may comprise a plurality of looped filaments that are substantially aligned such that each of the tunnel tufts has a different linear orientation and longitudinal axis L. By "endless" filaments, it is intended to mean tufted filaments that are integral with and start and end in a nonwoven layer, wherein they extend in the Z-direction (or negative Z-direction) from the first or second surface of the respective layer but generally outwardly. By "aligned" it is meant that the looped filaments are substantially all oriented such that, if viewed in plan view, each of the looped filaments has a significant vector component parallel to the transverse axis, and may have a major vector component parallel to the transverse axis. The transverse axis T is substantially orthogonal to the longitudinal axis in the MD-CD plane and the longitudinal axis is substantially parallel to the MD.

Due to plastic deformation of the filaments and the poisson's ratio effect, as shown in fig. 6A-6D, the elongation and/or crowding of the first and second pluralities of filaments may be accompanied by an overall reduction in the cross-sectional dimension of the filaments (e.g., the diameter of a round filament).

The tunnel tufts 270 and/or the outer tufts 230 can provide a masking benefit against liquid insults in the disposable absorbent article. Additionally, the tunnel clusters 270 and/or the outer clusters 230 may also provide softness benefits. The tunnel clusters 270 and/or the outer clusters 230 may be provided to the web material in any suitable configuration. Forms are contemplated in which the tunnel clusters 270 and/or the outer clusters 230 are arranged in zones and/or patterns. Such regions and patterns are described in more detail in U.S. patent application serial No. 14/933,017.

Tunnel cluster 270 and outer cluster 230, including methods of preparation, are discussed in more detail in U.S. patent 7,172,801; 7,838,099, respectively; 7,754,050, respectively; 7,682,686, respectively; 7,410,683, respectively; 7,507,459, respectively; 7,553,532; 7,718,243, respectively; 7,648,752, respectively; 7,732,657; 7,789,994, respectively; 8,728,049, respectively; and 8,153,226.

The tunnel clusters 270 and/or the outer clusters 230 may be used in conjunction with any of the holes, bond sites, embossments, and/or Z-direction feature differences described herein to create MD and/or CD feature differences. Or the tunnel cluster 270 and/or the outer cluster 230 may be utilized independently thereof.

A form of the invention is envisaged in which a web of material 10 of the invention comprising tunnel tufts and/or outer tufts is used as a topsheet in an absorbent article. In such forms, the tunnel tufts and/or the outer tufts may form a portion of the wearer-facing surface of the absorbent article-the tufts are oriented in the positive Z-direction. In other forms in which the web of material 10 is a topsheet, the web of material 10, along with underlying layers of the absorbent article, such as an acquisition layer, a secondary topsheet, may include tunnel tufts and/or outer tufts as described herein. In such forms, the underlying layer may form an outer tuft, and the tufts may be oriented in the negative Z-direction and positioned on the garment-facing side of the web material 10.

A form of the invention is envisaged in which either the first layer 20 or the second layer 30 is provided with tunnel clusters prior to forming the second layer 30 or the first layer 20 thereon, respectively. Forms are also envisaged in which the material web comprises at least a third layer in addition to the first 20 and second 30 layers. In such forms, the first and second layers may be provided with tunnel clusters prior to formation of the third layer thereon.

Filling cluster

Another way to create a characteristic difference in MD and/or CD is to use packed clusters. In contrast to the tunnel tufts 270 shown in fig. 6A-6E, webs of material of the present invention that include coiled filaments in the first or second plurality of filaments form discontinuity-filling tufts that are very different from those shown in fig. 6A-6E. Shown in fig. 7A-7D are schematic views of a web material 10 including filled tufts.

The web material 10 shown in fig. 7A-7D includes at least one layer that includes coiled filaments. As shown in fig. 7A, the second layer 30 includes a plurality of coiled filaments. As with the end portions 245 of some of the first plurality of filaments of the first layer 20 shown, the first layer 20 may not include coiled filaments. During the local pushing of the web of material 10 in the positive Z-direction, at least some of the first plurality of filaments may break to create end portions 245. As shown, the second plurality of filaments of second object layer 30 form a filled tuft 370 comprising a plurality of filaments filling the filled tuft 370. The packing clusters 370 may extend through the first layer 20. In some forms, as shown in fig. 7B, the first plurality of filaments may form an outer tuft 330 covering a fill tuft 370. And as shown in fig. 7C and 7D, the first plurality of filaments of the first layer 20 can, in some forms, form a packed tuft 370. In some forms, the second plurality of filaments of the second object layer 30 may form an outer tuft 330. In such forms, the web material 10 is subjected to localized jostling in the negative Z-direction.

As previously described with respect to "coiled filaments," the first plurality of filaments may be coiled and/or the second plurality of filaments may be coiled. For those forms in which web material 10 includes an additional layer, the constituent filaments of the additional layer may include coiled filaments.

In contrast to the tunnel tufts 270 (shown in fig. 6A-6E), the packing tufts 370 are substantially filled with looped filaments and/or non-looped filaments. In addition, unlike the alignment of the filaments with the transverse axis shown in fig. 6E, the coiled filaments of the packed clumps 370 may appear more random relative to the transverse axis T. And in contrast to the tunnel tufts 270 shown in fig. 6A-6E, it has been found that for the fill tufts 370, the constituent filaments often stretch from their crimped state rather than being stretched and attenuated.

The packed tufts 370 can be beneficial for those forms in which the second plurality of filaments forms the packed tufts 370 and for those forms in which the first plurality of filaments (at least a portion of which) break upon localized Z-direction extrusion. For example, if a first plurality of filaments does not produce a corresponding outer tuft 330, a liquid insult may readily reach a second plurality of filaments filling the tuft 370. And if the second plurality of filaments is hydrophilic-from the perspective of the filament composition and/or the perspective of the melt additive, the packed clumps 370 will provide additional surface area for the liquid to contact. Similarly, the filled clusters 370 can still provide strong liquid handling characteristics even in those forms where the corresponding outer clusters 330 are present.

In addition, where the web material of the present invention includes at least one layer having coiled filaments, the resulting web material has a higher thickness for a given basis weight. This higher thickness in turn delivers the following benefits to the consumer: comfort due to pad-like softness, faster absorption due to higher permeability, and improved masking. Additional benefits may include less red marking, higher breathability and resiliency.

A form of the invention is envisaged in which a web of material 10 comprising filled tufts and/or outer tufts is used as a topsheet in an absorbent article. In such forms, the infill and/or outer tufts may form a portion of the wearer-facing surface of the absorbent article-the tufts are directed toward the wearer of the article in the positive Z-direction. In other forms in which the web material 10 is a topsheet, the web material 10, along with underlying layers of the absorbent article, such as an acquisition layer, a secondary topsheet, may include the filled tufts and/or the outer tufts described herein. In such forms, the underlying layer may form an outer tuft, and the tufts may be oriented in the negative Z-direction and positioned on the garment-facing side of the web material 10.

Methods of making the packed clusters 270 and the outer clusters 330 are discussed in U.S. patent 7,172,801; 7,838,099, respectively; 7,754,050, respectively; 7,682,686, respectively; 7,410,683, respectively; 7,507,459, respectively; 7,553,532; 7,718,243, respectively; 7,648,752, respectively; 7,732,657; 7,789,994, respectively; 8,728,049, respectively; and 8,153,226. The padding clusters 370 and the corresponding outer clusters 330 are discussed in more detail in U.S. patent application serial No. 14/933,028.

The filled tufts 370 and/or the outer tufts 330 can be used in combination with any of the holes, bond sites, embossments, and/or Z-direction feature differences described herein to create MD and/or CD feature differences. Or the padding clusters 370 and/or the outer clusters 330 may be utilized independently thereof.

A form is envisaged in which the material web comprises at least a third layer in addition to the first 20 and second 30 layers. In such forms, the first and second layers may be provided with the packing clusters prior to forming the third layer thereon.

Nested cluster

Yet another way to generate MD and/or CD feature differences is through the use of nested clusters. Referring now to fig. 8A-8D, an example of a web material 10 including nested tufts 632 is shown. As previously described, web material 10 has a first surface 50, an opposing second surface 52, and a thickness T therebetween (thickness is shown in FIG. 8D). Fig. 8A shows first surface 50 of web material 10 with nested tufts 632 extending outward from first surface 50 of web material 10 (out of the plane of the sheet comprising fig. 8A). As shown, the web material 10 can include a generally planar first region 640 and a plurality of discrete integral second regions 642 comprising nested tufts 632.

As shown, the nested tuft 632 can have a width W that varies from one end 660 to an opposite end 660 when the nested tuft 632 is viewed in plan. As shown, the width W may be substantially parallel to the transverse axis TA. The width W can vary, with the widest portion of the nested tuft 632 in the middle of the nested tuft 632 and the width of the nested tuft 632 decreasing at the ends 660 of the nested tuft 632. In other cases, nested tuft 632 may be wider at one or both ends 60 than in the middle of nested tuft 632. In other cases, nested tufts 632 can be formed that have substantially the same width from one end of a nested tuft 632 to the other end of a nested tuft 632. If the width of a nested cluster 632 varies along the length of the nested cluster 632, the portion of the nested cluster 632 where the width is greatest is used to determine the aspect ratio of the nested cluster 632.

Similarly, nested tuft 632 can have a length L that is substantially parallel to longitudinal axis LA. When the nested tufts 632 have a length L that is greater than or less than their width W, the length of the nested tufts 632 can be oriented in any suitable direction relative to the web material 100. For example, the length of the nested tufts 632 (i.e., the longitudinal axis LA of the nested tufts 632) can be oriented in the MD, CD, or any desired orientation between the MD and CD. As shown, the transverse axis TA is generally orthogonal to the longitudinal axis LA in the MD-CD plane. In some forms as shown, the longitudinal axis LA is parallel to the MD.

In some forms, all of the spaced apart nested tufts 632 can have substantially parallel longitudinal axes LA.

Fig. 8B shows a second surface 52 of a web material 10, such as the second surface shown in fig. 8A, having nested tufts 632 formed therein, wherein the nested tufts 632 are oriented into the sheet shown in fig. 8B. The second surface 52 may include a plurality of base openings 644. In some forms, the base opening 644 may not be in the form of a hole or through-hole. The base opening 644 may instead appear as a recess.

In some forms, the base opening 644 can open into the interior of the nested cluster 632.

Referring to fig. 8A, 8C, and 8D, nested tufts 632 can have any suitable shape when viewed from the side. Suitable shapes include those wherein there is a distal portion or "cap" of enlarged size and a narrower portion at the bottom when viewed from at least one side. The term "cap" is similar to the cap portion of a mushroom. (the cap need not resemble a cap of any particular type of mushroom. furthermore, nested cluster 632 may (but need not) have a mushroom stem portion.) in some cases, nested cluster 632 may be referred to as having a bulbous shape when viewed from end 660. As used herein, the term "bulbous" is intended to refer to the configuration of nested tuft 632 with an enlarged scale top cap 652 and a narrower portion at the base when viewed from at least one side of nested tuft 632 (particularly when viewed from one of the shorter ends 660). The term "bulbous" is not limited to nested clusters 632 having a circular ring-shaped or circular plan-view configuration joined to a cylindrical portion. In the illustrated form, where the longitudinal axis LA of the nested tuft 632 is oriented in the longitudinal direction, the bulbous shape may be most pronounced if the cross-section is taken along the transverse axis TA (i.e., in the transverse direction) of the nested tuft 632. The bulbous shape may be less pronounced if the nested tuft 632 is viewed along the length (or longitudinal axis LA) of the nested tuft 632.

Referring to fig. 8A-8D, as discussed herein, the web of material 10 of the present invention includes a plurality of layers, and as shown, the individual layers may be designated 630A, 630B, etc. As shown, nested cluster 632 can include: a base 650 adjacent the first surface 50 of the web material 10; an opposite enlarged distal portion or cap portion or "cap" 652 extending to a distal end 654; side walls (or "sides") 656; an inner portion 658; and a pair of ends 660. The "base" 650 of the nested tuft 632 comprises the narrowest portion of the nested tuft 632 when viewed from one of the ends of the nested tuft 632. The term "cap" does not imply any particular shape, except that it includes a wider portion of the nested tuft 632 that includes and is adjacent to the distal end 654 of the nested tuft 632. The side walls 656 have an inner surface and an outer surface. The side walls 656 transition into the top cover 652 and may comprise a portion of the top cover. Therefore, it is not necessary to precisely define where the ends of the side walls 656 and the top 652 begin. The top cover 652 will have a maximum interior width W between the interior surfaces of the opposing sidewalls 656₁. The top cover 652 will also have a maximum outer width W between the outer surfaces of the opposing sidewalls 656. The ends 660 of the nested tufts 632 are the portions of the nested tufts 632 that are most spaced apart along the longitudinal axis L of the nested tufts 632.

Still referring to fig. 8A-8D, the narrowest portion of the nested cluster 632 defines a base opening 644. The base opening 644 has a width W_O. The base opening 644 can be located (in the Z-direction) between the plane defined by the second surface 52 of the web of material 10 and the distal ends 654 of the nested tufts 632. Web of material 10 can have an opening in second surface 52 that transitions into base opening 644 (and vice versa) and is the same size or larger than base opening 644. However, the base opening 644 will generally be discussed more frequently herein because in those embodiments in which the web material 10 is disposed in an article with a consumer-visible base opening 644, its size will often be more visually apparent to the consumer. It should be understood that in certain forms of the present invention, the base opening 644 faces outward (e.g., toward the consumer and away from the absorbent core in the absorbent article), and it is desirable that the base opening 644 is not covered and/or closed by another web.

The nested tuft 632 has a depth D measured from the second surface 30 of the web of material 100 to the interior of the nested tuft 632 at the distal end 654 of the nested tuft 632. The nested tufts 632 have a height H measured from the second surface 30 of the web material 100 to the exterior of the nested tufts 632 at the distal end 654. In most cases, the height H of nested tuft 632 will be greater than the thickness T of first region 640. The relationship between the various portions of the nested tuft 632, when viewed from the end, can be such that the maximum interior width W of the top cap 652 of the nested tuft 632 _IWider than the width W of the base opening 644_O。

In some cases, nested tufts 632 can be formed from looped filaments (which can be continuous) that are pushed outward such that they extend away from first surface 50 in the Z-direction or away from second surface 52 in the negative Z-direction. Nested tuft 632 will typically comprise more than one endless filament. In some cases, nested tufts 632 can be formed from looped filaments and at least some broken filaments. Further, in the case of some types of nonwoven materials (such as a spunlaid material comprising shorter filaments), nested tufts 632 can be formed from loops comprising a plurality of discontinuous filaments. A plurality of discontinuous filaments in the form of loops is described in U.S. patent application serial No. 14/844,459. The looped filaments can be aligned (i.e., oriented in substantially the same direction); are not aligned; or the filaments may be aligned in some locations within the protrusions 32 and not aligned in other portions of the protrusions.

In some forms, the filaments in at least a portion of nested tufts 632 can remain substantially randomly oriented (rather than aligned) similar to their orientation in the precursor web or webs. For example, in some cases, the filaments may remain in a substantially random orientation in the cap of the nested tuft 632, but more aligned in the sidewall such that the filaments extend from the base of the protrusion to the cap in the Z-direction (positive or negative depending on the orientation of the nested tuft 632). Further, the alignment of the filaments may vary between layers, and may also vary between different portions of a given nested tuft 632 of the same layer.

When the precursor web comprises a nonwoven material, the nested tufts 632 can comprise a plurality of filaments at least substantially surrounding the sides of the nested tufts 632. This means that there are a plurality of filaments that extend (e.g., in the positive or negative Z direction) from the base 650 of the nested tuft 632 to the distal end 654 of the nested tuft 632 and that help form a portion of the sides 656 of the nested tuft 632 and the cap 652. In some cases, the filaments may be substantially aligned with each other in the Z-direction in side 656 of nested tuft 632. Thus, the phrase "substantially surrounds" does not require that each filament be wrapped substantially or completely around the sides of the nested tuft 632 in the X-Y plane. If the filaments are positioned completely around the sides of the nested tuft 632, this would mean that the filaments are positioned 360 ° around the nested tuft 632. Nested tufts 632 may be free of large openings at their ends 660. In some cases, nested tufts 632 may have openings at only one of their ends, such as at their back ends.

In some forms, similarly shaped endless filaments may be formed in each layer of the multi-layer nonwoven material, including in the layer 630A that is spaced furthest from the discrete male forming elements during the process of forming the nested tufts 632 therein, and in the layer 630B that is closest to the male forming elements during the process. In nested clusters 632, portions of one layer, such as 630B, can fit within another layer, such as 630A. These layers may be referred to as forming a "nested" structure in nested clusters 632. The formation of a nested structure may require the use of two (or more) highly extensible nonwoven precursor webs. In the case of two layers of material, the nested structure may form two complete loops, or (as shown in some of the following figures) two incomplete filament loops.

Nested cluster 632 may have some additional features. As shown in fig. 8C and 8D, nested cluster 632 can be substantially hollow. As used herein, the term "substantially hollow" refers to the structure: nested tuft 632 is substantially free of filaments in the interior of the nested tuft. However, the term "substantially hollow" does not require that the nested tufts be completely free of filaments. Thus, there may be some filaments within the nested tuft 632. "substantially hollow" nested tufts can be distinguished from filled three-dimensional structures, such as those made by laying down filaments, such as by air-laying or carding the filaments onto a forming structure with recesses therein.

The sidewalls 656 of the nested tufts 632 can have any suitable configuration. The configuration of the sidewalls 656 can be linear or curvilinear when viewed from the end of a nested tuft such as shown in fig. 8C, or the sidewalls can be formed from a combination of linear and curvilinear portions. The curved portion may be concave, convex, or a combination of both. For example, the side walls 656 can include a curved inwardly concave portion near the base of the nested tuft and an outwardly convex portion near the top of the nested tuft. The sidewalls 656 and the area surrounding the base opening 644 of the nested tuft can have a significantly lower concentration of filaments per given area (which can be evidence of a lower basis weight or lower opacity) than portions of the first region 640. Nested tufts 632 can also have attenuated filaments in the sidewalls 656. The attenuation of the filaments, if present, will be evident in the filaments in the form of necked regions. Thus, the filaments can have a first cross-sectional area when they are in the undeformed precursor material 102 and a second cross-sectional area in the sidewalls 656 of the nested tufts 632 of the deformed web material 10, wherein the first cross-sectional area is greater than the second cross-sectional area. The sidewalls 656 can also include a number of broken filaments. In some forms, the sidewalls 656 can comprise greater than or equal to about 30%, alternatively greater than or equal to about 50%, broken filaments.

In some forms, the distal end 654 of the nested tuft 632 may comprise an original basis weight, non-elongated filaments, and non-broken filaments. If the base opening 644 is facing upward, the distal end 654 will be located at the bottom of the recess formed by the nested tufts. The distal end 654 will be free of holes formed completely through the distal end. Thus, the nonwoven material may be non-perforated. As used herein, the term "apertures" refers to apertures formed in a nonwoven after the nonwoven is formed, and does not include apertures typically present in nonwovens. The term "apertures" also does not refer to irregular breaks (or interruptions) in one or more nonwoven materials that result from localized tearing of one or more materials during the process of forming nested clusters therein, which breaks can be attributed to variability in one or more precursor materials. The distal end 654 may have a relatively greater concentration of filaments than the remainder of the structure forming the protrusions. Filament concentration can be measured by observing the sample under a microscope and counting the number of filaments in a certain area.

Nested tufts 632 can have any suitable shape. Since nested clusters 632 are three-dimensional, describing their shape will depend on the angle at which they are viewed. Suitable shapes when viewed from above (i.e., perpendicular to the plane or plan view of the web), such as in fig. 8A, include, but are not limited to: circular, diamond, round diamond, football, oval, clover, heart, triangle, teardrop, and oval. In other cases, nested cluster 632 can be non-circular. Nested clusters 632 may have similar plan view dimensions in all directions, or nested clusters 632 may be longer in one dimension than in another. That is, nested clusters 632 may have different length and width dimensions. If nested cluster 632 has a length that is different than the width, the longer dimension will be referred to as the length of nested cluster 632. Thus, nested cluster 632 can have a ratio of length to width, or aspect ratio. The aspect ratio may range from about 1:1 to about 10: 1.

In some forms, the length of the cap 652 may be in the range of about 1.5mm to about 10 mm. In some forms, the width of the cap (measured where the width is greatest) may range from about 1.5mm to about 5 mm. The cap portion of the protrusion may have at least about 3mm²Area of the plane diagram. In some embodiments, the protrusion may have a pre-compression height H in a range of about 1mm to about 10mm, alternatively about 1mm to about 6 mm. In some embodiments, the protrusions may have a post-compression height H in the range of about 0.5mm to about 6mm, alternatively about 0.5mm to about 1.5 mm. In some embodiments, the protrusions may have a depth D in the uncompressed state in a range of about 0.5mm to about 9mm, alternatively about 0.5mm to about 5 mm. In some forms, the protrusion may have a post-compression depth D in a range of about 0.25mm to about 5mm, alternatively about 0.25mm to about 1 mm.

A method of forming nested clusters is disclosed in U.S. patent application publication 2016/0074256. For webs of material of the present invention, the first layer may be incorporated into an absorbent article as, for example, an acquisition layer, and the second layer may be a topsheet of the absorbent article. Each of the first and second layers may form nested clusters that fit into each other. Additional forms are envisaged in which the web of material of the present invention comprises multiple layers and forms a topsheet and is subsequently processed together with the acquisition layer.

A form is envisaged in which the material web comprises at least a third layer in addition to the first 20 and second 30 layers. In such forms, the first and second layers may be provided with nested tufts prior to formation of the third layer thereon.

Mixed cluster

The web material 10 shown in fig. 44 includes hybrid clusters 770, each having a corresponding opening 285. The material of the first layer 20 may be removed by ablation or other very carefully performed process such that the material of the second layer 30 is exposed through the end 245 of the material of the first layer 20. Alternatively, as previously described, the first layer 20 may be subjected to a process that forms holes in the first layer 20. Subsequently, a second layer 30 may be formed on the first layer 20.

Additionally, in some forms, the material of the second layer 30 may be pushed in the positive Z-direction such that the distal ends of the hybrid clumps 770 are substantially coplanar with the first surface 50 of the web material 10.

In such forms, the web material 10 may form a portion of a topsheet of an absorbent article. The first layer 20 may be more hydrophobic than the second layer.

Outer cluster, tunnel cluster, filling cluster, nested cluster and mixed cluster

The tunnel, filled, outer, nested, and intermingled tufts of the web material of the present invention are believed to be capable of masking or partially masking the fluid collected by the web material and retained in the capillaries between the filaments of the tunnel, filled, outer, or nested tufts, and of masking the liquid absorbed in the absorbent layer (which is undesirably discolored by the liquid) beneath the structure that includes these characteristic differences. Such webs of material used in absorbent articles such as wipes, sanitary napkins, tampons, or diapers can be attractive to users (or caregivers) because potentially unsightly fluid retained in the capillaries between the filaments of the various tufts will be masked or partially masked by the viewer. The clusters may cover or partially cover the gaps in which the fluid may be held. Such features may make the web of material appear to be less prone to soiling. One additional benefit of the tufts described herein is the soft feel produced by the tufts.

The outer clusters, tunnel clusters, padding clusters, nested clusters, hybrid clusters may be spaced apart from adjacent clusters. Each of the spaced apart tufts has a generally parallel longitudinal axis L. The number of tufts per unit area of the web material of the present invention, i.e. the areal density of the tufts and/or the cap, can vary from one tuft per unit area, e.g. square centimeter, up to 100 tufts per square centimeter. There can be at least 10, or at least 20 tufts per square centimeter, depending on the end use. Generally, the areal density need not be uniform over the entire area of the web material of the present invention, and in some embodiments, the tufts may be present only in certain areas of the web material of the present invention, such as in areas having a predetermined shape, such as lines, stripes, bands, circles, and the like.

Outer clusters, tunnel clusters, packed clusters, nested clusters, and hybrid clusters can affect permeability in the MD and/or CD direction regions. Thus, certain areas of the web material, particularly where tufts are disposed, may experience higher permeability and have a different texture than the generally planar first and/or second surfaces. Corrugations and grooves (described below) can similarly affect the web material of the present invention in terms of permeability and texture.

Additionally, if the web material of the present invention is incorporated into an absorbent article, the tufts and/or corrugations and channels described herein can be formed in additional layers of the web material as well as the absorbent article. For example, if the web of material of the present invention is utilized to form a portion of a topsheet of an absorbent article, tufts and/or corrugations and grooves may be formed in the underlying fluid handling layer between the topsheet and the absorbent core in addition to being formed in the web of material. In one particular example, the tufts and/or corrugations and grooves may be formed in a web of material that is bonded to an acquisition layer. In another specific example, the tufts and/or corrugations and grooves may be formed in a web of material that is bonded to the secondary topsheet. In such forms, the fluid handling layer may form an outer tuft that covers the tufts created by the web of material. In contrast, forms are envisaged in which the fluid-handling layer forms a tunnel cluster, while the web of material forms an outer cluster or simply a discontinuity through which the tunnel cluster extends.

Tunnel clusters, infill clusters, outer clusters, hybrid clusters, and/or nested clusters can be used in conjunction with, or independently of, any of the holes, bond sites, embossments, and/or Z-direction feature differences disclosed herein.

Wave like

Yet another way to create feature differences in the MD and/or CD is through the use of corrugations. The nonwoven web 10 of the present invention may include corrugations on the first surface 50 and the second surface 52. Some exemplary corrugations are shown in fig. 9A-9D. As shown, the web material 10 of the present invention can include corrugations 670 and grooves 675 disposed between adjacent corrugations 670. The corrugations 670 may extend in a direction generally parallel to the MD or generally parallel to the CD. The corrugations 670 and/or the grooves 675 can include any suitable shape. For example, as shown, the corrugations 670 may have an arcuate shape. As another example, the corrugations 670 may include a triangular shape. Additionally, examples are also contemplated in which a web of material constructed in accordance with the present invention includes at least one corrugation having an arcuate shape and one ridge comprising a triangular shape.

The use of corrugations 670 can provide softness benefits to the web material 10. Additionally, the web material 10 may also have a higher permeability in the corrugations 670. Additional details regarding corrugation 670, including suitable processes for forming corrugation 670, can be found in U.S. patent 6,458,447; 7,270,861, respectively; 8,502,013, respectively; 7,954,213, respectively; 7,625,363, respectively; 8,450,557, respectively; and 7,741,235. Additional suitable processes and structures are described in the following patents: U.S. patent application publication US 2003/018741; US 2009/0240222; US 2012/0045620; US 20120141742; US 20120196091; US 20120321839; US 2013/0022784; US 2013/0017370; US 2013/013732; US 2013/0165883; US 2013/0158497; US 2013/0280481; US 2013/0184665; US 2013/0178815; and US 2013/0236700. Other additional suitable processes and structures are described in relation to the following patents: PCT patent application publication WO 2008/156075; WO 2010/055699; WO 2011/125893; WO 2012/137553; WO 2013/018846; WO 2013/047890; and WO 2013/157365.

Referring to fig. 37, in some forms, a web material of the present invention can include corrugations extending in the MD and CD. As shown, the plurality of corrugations 3770 can include a distal end 3754 and a sidewall 3756. Adjacent discrete protrusions 3770 may be separated by grooves 3775 that extend in both the MD and CD directions. Distance D1 represents the length in MD of the distal end 3754 of corrugation 3770. The distance D2 is the length of the corrugation in the MD as measured between adjacent grooves 3775. In some forms, D1 may be equal to D2 depending on the formation of the processing regime that produces web material 10. In other forms, D2 may be greater than D1.

Distance D3 is the length between adjacent corrugations 3770 of the MD, as measured from the plane containing distal end 3754. Distance D3 may be any suitable distance. Distance D6 is the width between adjacent corrugations 3770 of the CD, as measured from the plane containing distal end 3754.

Distance D4 is the width in CD of distal end 3754 of corrugation 3770. The distance D5 is the width in CD of the corrugation as measured between adjacent grooves 3775. In some forms, D4 may be equal to D5 depending on the formation of the processing regime that produces web material 10. In other forms, D4 may be less than D5.

A suitable apparatus for forming corrugations 3770 in the web material 10 of the present invention is described in U.S. patent application publication 2009/0240222. In such forms, the corrugations may be provided as discrete elements in the MD and CD directions.

Additional configurations for the corrugations are contemplated. Some suitable examples of corrugations are disclosed in U.S. patent application 2004/0137200. As shown in fig. 38, the web material 10 of the present invention can include a plurality of discrete corrugations 3770.

An additional configuration of a web material 10 for use in the present invention is also shown in fig. 39. As shown, in some forms, the corrugations 3770 can extend in the CD across the width of the web material 10. However, the trenches 3775 between adjacent corrugations 3770 can be wider than those shown in the previous figures. Additionally, an aperture 3725 may also be provided in the trench 3775. Processes for forming such webs of material are described in more detail in U.S. patent application publication 2012/0276331.

For each of the web materials 10 shown in fig. 37-39, the process for forming each of these web material configurations involves the use of intermeshing rolls. In such forms, the resulting corrugations may have localized regions of high and lower thickness and alternating regions of higher and lower basis weight. Regions of higher thickness and higher basis weight can be disposed at the distal ends 3754 of the corrugations 3770 and in the grooves 3775. In contrast, the sidewalls 3756 may be provided with a lower thickness and lower basis weight.

The corrugations may be utilized in conjunction with any of the holes, embossments, bond sites, tufts (all kinds), and) or Z-direction feature differences disclosed herein, or may be used independently thereof.

Zone(s)

The MD and/or CD characteristic differences discussed herein, such as holes, bond sites, embossments, tunnel tufts, infill tufts, nested tufts, corrugations, and/or channels, can be provided in the zones to create additional characteristic differences in the MD and/or CD of the web material. The zones in the web material of the present invention may be oriented in the machine direction, cross-machine direction, or may be concentric. If a product, such as an absorbent article, has two distinct zones in the longitudinal direction, these zones may have the same or similar transverse width (e.g. +/-2mm) to facilitate processing. One or more of the zones may have curved or straight boundaries or partial boundaries.

Any suitable number of zones for a web of material including more than two distinct or identical zones is contemplated within the scope of the present disclosure. The various zones may be in the topsheet as mentioned above, but may also be present on the outer cover or cuffs, for example. In some cases, the same or different patterns of zones of web material may be used on the wearer-facing surface (e.g., topsheet) and the garment-facing surface (e.g., outer cover).

In one example, a topsheet or other portion of an absorbent article may have two or more zones in the web of material. For example, a first region of the web material may have a different discontinuity than a second region. The first and second regions may have different functions due to the different discontinuities. The first zone may function to provide distribution of liquid bodily exudates (fluid moving on the web of material) and the second zone may function to provide acquisition of liquid bodily exudates (fluid pervious web of material). The benefits of such zoned material webs can be better use of the absorbent core and more efficient distribution of liquid bodily exudates within the absorbent core. This is particularly desirable if a non airfelt-containing core is used, because typical non-airfelt-containing cores strive to dispense liquid bodily exudates to some extent once the liquid bodily exudates are received therein.

As previously mentioned, the web material of the present invention can be used in several different components of an absorbent article. Referring to fig. 10, in one specific example, a disposable absorbent article utilizing a web material of the present invention may include a plurality of zones. As shown, the topsheet 2014 of the disposable absorbent article 2010 can include a first zone 2007, a second zone 2011, and a third zone 2013. The absorbent article may include more zones or fewer zones, as described below.

The first zone 2007 may include a first plurality of discontinuities, such as holes. As shown, the first zone 2007 may have a width parallel to the lateral axis 2090 that does not extend the full width of the topsheet 2014. Conversely, the second zone 2011 and the third zone 2013 may be disposed on either side of the first zone 2007. In some forms, the second zone 2011 and the third zone 2013 may include a second plurality of discontinuities. In some forms, the first plurality of discontinuities may be different than the second plurality of discontinuities. For example, the first plurality of discontinuities may include holes, while the second and third regions include tunnel clusters. Additional forms are contemplated in which the first zone 2007, the second zone 2011, and/or the third zone 2013 can include additional pluralities of discontinuities. For example, the first zone 2007 may include a plurality of apertures and a plurality of bond sites. As another example, the second zone 2011 and/or the third zone 2013 may include a plurality of tunnel clusters and a plurality of bond sites. Additional discontinuities are contemplated. For example, the first zone 2007, the second zone 2011, and/or the third zone 2013 may additionally include a plurality of embossed portions.

Suitable configurations of the zones are described in relation to fig. 11-14. Fig. 11-14 can represent a portion of the wearer-facing surface of an absorbent article, such as a diaper, adult incontinence product, and/or sanitary napkin.

Fig. 11 shows an example of a substrate having three zones. The front portion F may be positioned in the front of the absorbent article or in the back of the absorbent article. The back portion B may be positioned in the front of the absorbent article or in the back of the absorbent article. The first region 4004 and the second region 4006 can be positioned intermediate two portions of the third region 4008. The first region 4004 may include a first plurality of discontinuities as described above. The second region 4006 can comprise a second plurality of discontinuities. In some forms, the first plurality of discontinuities may be different than the second plurality of discontinuities. As shown, a substantially laterally extending separation element 4010 can extend between the intersection of the first region 4004 and the second region 4006.

In another case, still referring to fig. 11, the first region 4004 can comprise patterned discontinuities, such as holes, wherein at least two of the patterned holes have different sizes, shapes, and/or orientations. The pattern of apertures may be any of the various patterns described herein or other suitable patterns. The second region 4006 can comprise a pattern of holes, wherein at least two holes in the pattern of holes have different sizes, shapes, and/or orientations. The pattern of apertures may be any of the various patterns described herein or other suitable patterns. The second region 4006 may have a different or the same hole pattern as the first region 4004. The third region 4008 can comprise a plurality of discontinuities. The out-of-plane deformations may extend up out of the page or down into the page. A substantially laterally extending separation element 4010 can extend between the intersection of the first region 4004 and the second region 4006.

Fig. 12 shows an example of a substrate having a first region 4012 and a second region 4014. The front portion F may be positioned in the front of the absorbent article or in the rear of the absorbent article. The back portion B may be positioned in the front of the absorbent article or in the back of the absorbent article. The first region 4012 can comprise patterned apertures, wherein at least two of the patterned apertures have different sizes, shapes, and/or orientations. The pattern of apertures may be any of the various patterns described herein or other suitable patterns. The second region 4014 may comprise a plurality of discontinuities. A substantially laterally extending separation element 4010 can extend between the intersection of the first region 4012 and the second region 4014.

In another instance, still referring to fig. 12, the second region 4014 can comprise patterned apertures, wherein at least two of the patterned apertures have different sizes, shapes, and/or orientations. The pattern of apertures may be any of the various patterns described herein or other suitable patterns. The first region 4012 may comprise a plurality of discontinuities. A substantially laterally extending separation element 4010 can extend between the intersection of the first region 4012 and the second region 4014.

Fig. 13 shows an example of a web material having a first zone 4016 and a second zone 4018. The front portion F may be positioned in the front of the absorbent article or in the rear of the absorbent article. The back portion B may be positioned in the front of the absorbent article or in the back of the absorbent article. The second region 4018 may at least partially or completely surround the first region 4016.

Still referring to fig. 13, the first region 4016 can comprise a plurality of discontinuities. The second region 4018 may comprise a plurality of discontinuities. The second zones 4018 may have a different or the same pattern, shape, size, and/or orientation of discontinuities as compared to the pattern, shape, size, and/or orientation of the discontinuities of the first zones 4016.

In another instance, still referring to fig. 13, the first region 4016 can comprise patterned apertures, wherein at least two of the patterned apertures have different sizes, shapes, and/or orientations. The pattern of apertures may be any of the various patterns described herein or other suitable patterns. The second region 4018 may comprise a plurality of discontinuities.

In yet another instance, still referring to fig. 13, the second region 4018 can comprise patterned apertures, wherein at least two of the patterned apertures have different sizes, shapes, and/or orientations. The first region 4016 may comprise a plurality of discontinuities.

In another instance, still referring to fig. 13, the first region 4016 can comprise patterned apertures, wherein at least two of the patterned apertures have different sizes, shapes, and/or orientations. The pattern of apertures may be any of the various patterns described herein or other suitable patterns. The second region 4018 can comprise patterned apertures, wherein at least two of the patterned apertures have different sizes, shapes, and/or orientations. The pattern of apertures may be any of the various patterns described herein or other suitable patterns. The pattern of apertures of the first region 4016 and the second region 4018 can be different or the same.

FIG. 14 shows an example of a web material having first regions 4020 and second regions 4022. The front portion F may be positioned in the front of the absorbent article or in the rear of the absorbent article. The back portion B may be positioned in the front of the absorbent article or in the back of the absorbent article. The second regions 4022 may at least partially or completely surround the first regions 4020.

Still referring to fig. 14, the first regions 4020 may comprise patterned apertures, wherein at least two of the patterned apertures have different sizes, shapes, and/or orientations. The second regions 4022 may comprise patterned apertures, wherein at least two of the patterned apertures have different sizes, shapes, and/or orientations. The pattern of apertures may be any suitable pattern. The pattern of apertures of the first regions 4020 and the second regions 4022 may be different or the same.

Still referring to fig. 14, the first regions 4020 may comprise patterned apertures, wherein at least two of the patterned apertures have different sizes, shapes, and/or orientations. The pattern of apertures may be any of the various patterns described or other suitable patterns. The second regions 4022 may comprise a plurality of discontinuities.

Still referring to fig. 14, the second regions 4022 may comprise patterned apertures, wherein at least two of the patterned apertures have different sizes, shapes, and/or orientations. The pattern of apertures may be any suitable pattern. The first regions 4020 may comprise a plurality of discontinuities.

Still referring to fig. 14, the first regions 4020 may include a plurality of discontinuities. The second regions 4022 may comprise a plurality of discontinuities. The second regions 4022 may have a different or the same pattern, shape, size, and/or orientation of discontinuities as compared to the pattern, shape, size, and/or orientation of the discontinuities of the first regions 4020.

Patterned holes and patterned discontinuities are disclosed in more detail in U.S. patent application serial No. 14/933,028; 14/933,017, respectively; and 14/933,001. The discontinuities described herein may be configured in any suitable manner to achieve the desired acquisition, rewet, and softness characteristics for the web material. And as previously described, discontinuities can be utilized in conjunction with Z-direction gradient filament characteristics to similarly achieve the desired acquisition, rewet, and/or softness of the web material of the present invention.

Examples

Example 1

A25 gsm (grams/m) test line of the present invention was prepared on a 1 meter wide test line at Reifenhauser, GmbH (Teloesdofur, Germany)²) Nonwoven webs (about 12.5gsm in the first manifold and about 12.5gsm in the second manifold). An 60/40 paral-lel PP of about 20.5 microns diameter was spun in a first spin pack containing 12.5gsm ₁/PP₂And (3) filaments. The two components additionally contained 16% Techmer PPM17000 high loading (40%) hydrophobic masterbatch and the second component contained 1.5% TiO2 masterbatch. In a second spinning box, 70/30 paral PP with a diameter of about 18 microns was spun₁/PP₂And (3) filaments. The two components from the second spin pack additionally contained 2.0% Techmer^TMPPM15560 hydrophilic masterbatch and the first component additionally contained 1.0% TiO2 masterbatch. The first and second layers were calendar bonded with a dot bond pattern having a bond area of 12%.

Fig. 15A-15C are SEM photographs showing the first and second layers 20 and 30. Fig. 15A is an SEM photograph of a portion of the first plurality of filaments of first layer 20, and fig. 15B is an SEM photograph of a portion of the second plurality of filaments of second layer 30. As shown, the hydrophobic melt additive of the first plurality of filaments is present as a combination of a plurality of fibrils.

Examples 2, 3, 4 and 5

For each of examples 2, 3, 4 and 5, all materials were prepared on a 1 meter wide pilot line at Reicofil (taloesdofv, germany) and they each included 2 denier per filament 70/30 side-by-side PP1/PP2 filaments.

Example 2

A web material according to the present disclosure is prepared having a basis weight of 40gsm with about 50% included in the first layer and about 50% included in the second layer. The nonwoven webs were prepared from two spinning beams. The first layer comprises hydrophobic filaments The first polypropylene component of the first plurality of filaments comprises 16 wt% of a second polypropylene component from Techmer^TMPPM1700 highly loaded hydrophobic master batch and 1 wt% TiO2 master batch. The second layer comprises hydrophilic filaments, wherein the first polypropylene component and the second polypropylene component each additionally comprise 2% by weight of a polymer derived from Techmer^TMPPM 15560 hydrophilic masterbatch. The first polypropylene component additionally comprises 1 wt% of a masterbatch.

Example 3

A laminate comprising a pair of spunbond hydrophobic webs, wherein each of the spunbond hydrophobic webs was prepared at a total basis weight of 25 gsm. The two hydrophobic webs each comprise the same filament size and filament composition. In filaments, both the first polypropylene component and the second polypropylene component additionally contained 16 wt% of PPM1700 highly loaded hydrophobic masterbatch from Techmer. The first polypropylene component additionally contained 1 wt% of a TiO2 masterbatch.

Example 4

A laminate comprising a pair of spunbond hydrophilic webs, wherein each of the spunbond hydrophilic webs was prepared at a total basis weight of 25 gsm. The two hydrophilic webs each comprise the same filament size and filament composition. In filaments, both the first polypropylene component and the second polypropylene component additionally contained 2 wt% of PPM 15560 hydrophilic masterbatch from Techmer. The first polypropylene component additionally contained 1 wt% of a TiO2 masterbatch.

Example 5

A nonwoven laminate was prepared comprising one of the pair of nonwoven webs of example 3 (25gsm) and one of the pair of nonwoven webs of example 4 (25gsm), resulting in a 50gsm laminate comprising a hydrophobic web over a hydrophilic web.

Data 1-unmodified web/laminate

Table 1 shows the basis weight, rewet, and acquisition data for examples 2, 3, 4, and 5. None of these embodiments include holes or any other interruptions as described herein.

Material	Total basis weight (gsm)	Return osmosis (Ke)	Inrush current collection time (seconds)
				Example 2	40	0.45	803
Example 5	50	0.36	790
				Example 3	50	0.21	803
Example 4	50	0.67	801

TABLE 1

As shown, the unmodified nonwoven web of the present invention (example 2) exhibited better performance from a rewet point of view than the hydrophilic laminate (example 4). The acquisition time for example 2 was similar to the acquisition time for the hydrophobic laminate (example 3).

Data 2-apertured webs/laminates

The above embodiments are apertured as described herein. Example 2 photographs of example 5 are provided in relation to fig. 16A-16B, respectively. Both the web of material 10 and the nonwoven laminate 1100 include apertures 125 as disclosed herein.

Table 2 shows the basis weight, rewet, and acquisition data for examples 2, 3, 4, and 5. Each of these embodiments includes an aperture as described herein. The hole size is about 2.5mm in length and about 0.3 to about 0.35mm in width.

Material	Total basis weight (gsm)	Return osmosis (Ke)	Inrush current collection time (seconds)
				Example 2 perforation	40	0.53	235
Example 5 perforation	50	0.15	226
				Example 3 perforation	50	0.32	501
Example 4 perforation	50	1.04	134

TABLE 2

As shown, the web material of the present invention (example 2) exhibited better performance from a rewet point of view than the hydrophilic laminate (example 4). The acquisition time for example 2 was much better than for the hydrophobic laminate (example 3). The acquisition time of example 2 was similar to that of example 5. And as noted above, the apertures can affect the acquisition rate of the web material. Without being bound by theory, it is believed that there may be a balance between collection and rewet. While the apertures reduce acquisition time, which may be desirable in absorbent articles, the addition of apertures may increase rewet as compared to the non-apertured version of example 2.

Data 3-tufted Web/laminate

The above examples are clustered as described herein. Each of these embodiments includes a cluster. Example 2 SEM photographs of example 5 are provided in association with fig. 17A-17B, respectively. Both the web of material 10 and the nonwoven laminate 1100 include tufts 270 as disclosed herein.

Table 3 shows the basis weight, rewet, and acquisition data for examples 2, 3, 4, and 5. Each of the embodiments includes an aperture as described herein.

Material	Total basis weight (gsm)	Return osmosis (Ke)	Inrush current collection time (seconds)
				Example 2 tufting	40	0.33	227
Example 5 tufting	50	0.34	178
				Example 3 tufting	50	0.47	312
Example 4 tufting	50	0.85	92

TABLE 3

As shown, the web material of the present invention (example 2) exhibited better performance from the standpoint of rewet than the hydrophilic laminate (example 4) and the hydrophobic laminate (example 3). The acquisition time for example 2 was much better than for the hydrophobic laminate (example 3). The acquisition time of example 2 was similar to that of example 5. Thus, contrary to common sense, a single layer topsheet may function adequately from the acquisition and rewet point of view. Whether open-celled or clustered, the modified embodiments provide faster fluid acquisition rates relative to their unmodified counterparts. In addition, as shown in table 3, the web material of the present invention may also provide reduced rewet.

The above data indicate that when Z-direction feature differences, MD and/or CD feature differences such as holes, tufts are utilized, the web material of the present invention can behave similarly to a laminate made from two separate webs (example 5).

An additional benefit of the web material of the present invention includes the integral formation of the first and second layers. This integral formation may facilitate the production of absorbent articles comprising the web material of the present invention. In contrast, since the laminate includes separate nonwoven layers, additional equipment is required to form the laminate. For example, equipment is required to provide the two separate layers to the converting process. For high speed manufacturing care must be taken to ensure that the two component layers of the laminate are offset within the desired tolerances. However, as previously mentioned, the web material of the present invention is integrally formed. Therefore, the additional equipment required for forming the nonwoven laminate is not required for the web material of the present invention.

Additional embodiments are contemplated

Fig. 40 and 41 show a cross-sectional view of a spunbond-meltblown-spunbond (SMS) web and a cross-sectional view of the web, respectively, at calender bond site 4068, according to the present disclosure. A three layer web material 4012 made by the process described herein is shown. The web material 4012 can comprise a first nonwoven composition layer 4020 which can itself comprise, for example, spunbond fibers. The web material 4012 can comprise a second nonwoven composition layer 4025 which can itself comprise meltblown fibers. The meltblown layer may include fibers of intermediate diameter, which may include fibers having an average or number average diameter in the range of 0.7 microns to 8 microns, alternatively in the range of 1 micron to 8 microns, and alternatively in the range of 1 micron to 5 microns, with a relative standard deviation in the range of 20% to over 100%. The web material 4012 can comprise a third nonwoven layer 4030 that itself comprises spunbond fibers. In some forms, first layer 4020 and third layer 4030 may be similar, or in other forms, first layer 4020 and third layer may be different as described herein.

Referring to fig. 42 and 43, a web of material 4200 is shown. As shown, in some forms of the invention, the web material 4200 can include a first nonwoven composition layer 4020 comprising fibers having an average diameter in a range from 8 microns to 30 microns; a second nonwoven composition layer 4025 comprising fibers having a number average diameter of less than 1 micron, a mass average diameter of less than 1.5 microns, and a polydispersity ratio of less than 2; a third nonwoven composition layer 4027 comprising fibers having an average diameter ranging from 8 microns to 30 microns; and a fourth nonwoven composition layer 4030 comprising fibers having an average diameter in the range of 1 micron to 8 microns. In other words, web material 4200 can include a first nonwoven layer 4020 comprising fibers having an average denier in the range of 0.4 to 6; a second nonwoven composition layer 4025 comprising fibers having an average denier in the range of 0.00006 to 0.006; a third nonwoven layer 4027 comprising fibers having an average denier in the range of 0.4 to 6; and a fourth nonwoven layer 4030 comprising fibers having an average denier in the range of 0.006 to 0.4. In such forms, the second nonwoven layer 4025 and the fourth nonwoven composition layer 4030 may be disposed between the first nonwoven composition layer 4020 and the third nonwoven composition layer 4027. In addition, the first nonwoven composition layer 4020, the second nonwoven layer 4025, the third nonwoven composition layer 4027, and the fourth nonwoven composition layer 4030 may also be intermittently bonded to each other using any bonding process, such as a calender bonding process.

In various forms, the web material of the present invention can include a spunbond layer that can correspond to the first nonwoven composition layer 4020, a meltblown layer that can correspond to the second nonwoven composition layer 4025, a nanofiber layer that can correspond to the third nonwoven composition layer 4027, and a second spunbond layer that can correspond to the fourth nonwoven composition layer 4030, which together are referred to herein as "SMNS webs". Additional configurations are contemplated. Some examples include webs of materials comprising a spunbond layer, a meltblown layer, a nanofiber layer, a second spunbond layer, and a third spunbond layer having, for example, different structures or compositions.

Without being bound by theory, it is believed that the inclusion of the nanofiber layer within the web allows the web to maintain desirable low surface tension fluid strikethrough times and air permeabilities without the need for any hydrophobic materials. It is also believed that the nanofiber layer reduces the pore size of the web by organizing the voids within the spunbond layer and the meltblown layer. By creating a web with smaller pore sizes compared to the pore sizes of the associated web, the webs of the present disclosure can have higher capillary resistance to fluid penetration and thus longer low surface tension fluid strike-through times, even without the inclusion of hydrophobic materials.

Additional contemplated embodiments of the present invention are described below.

Example A: an absorbent article comprising a topsheet, and a backsheet, and an absorbent core disposed between the topsheet and the backsheet, and further comprising a web of material having a first surface and a second surface, a Machine Direction (MD) and a cross-direction (CD) perpendicular to the MD, and a Z-direction perpendicular to a plane containing the MD and CD, the web of material further comprising: a first layer comprising a first plurality of filaments, the first layer forming a first surface; and a second layer comprising a second plurality of filaments, the second layer forming a second surface; wherein the first layer and the second layer are integrally formed, and wherein the first plurality of filaments are spunbond, and wherein the web of material further comprises a Z-direction characteristic difference and an MD and/or CD characteristic difference.

Example a 1: the absorbent article of embodiment a, wherein the first plurality of filaments differs from the second plurality of filaments by at least one of: surface energy, filament size, filament cross-sectional shape, filament crimp, softness, and filament composition.

Example a 2: the absorbent article of embodiment a-a1, wherein the first plurality of filaments comprises a hydrophobic melt additive.

Example a 3: the absorbent article of embodiments a-a2, wherein the second plurality of filaments comprises a hydrophilic melt additive.

Example a 4: the absorbent article of embodiments a-a3, wherein the first plurality of filaments comprises a first denier and the second plurality of filaments comprises a second denier, wherein the first denier is greater than the second denier.

Example a 5: the absorbent article of embodiments a-a3, wherein the first plurality of continuous filaments comprises a first denier and the second plurality of continuous filaments comprises a second denier, wherein the first denier is less than the second denier.

Example a 6: the absorbent article of embodiments a-a5, further comprising a third article layer having a third plurality of filaments, wherein the third article layer is different from the first layer and/or the second layer, and wherein the third article layer is integrally formed with the first layer and the second layer.

Example a 7: the absorbent article of embodiments a-a6, wherein the first and second plurality of filaments comprise at least one of: a filament configuration, a monocomponent, a bicomponent side-by-side, or a bicomponent sheath-core, and wherein the filament configuration of the first plurality of continuous filaments is different from the filament configuration of the second plurality of continuous filaments.

Example A8: the absorbent article of embodiments a-a7, wherein the first plurality of filaments and the second plurality of filaments comprise monocomponent or bicomponent filaments, and wherein the bicomponent filaments comprise at least one of: a combination of polyethylene/polypropylene polymer, polypropylene polymer/polypropylene polymer, or polypropylene polymer/polylactic acid, and wherein the first plurality of filaments is different from the second plurality of filaments.

Example a 9: the absorbent article of embodiments a-A8, wherein the first plurality of filaments or the second plurality of filaments comprise coiled filaments, but not both.

Example a 10: the absorbent article of embodiment a-A8, wherein the first plurality of filaments and the second plurality of filaments comprise crimped filaments, and wherein the first plurality of continuous filaments or the second plurality of continuous filaments comprise a higher degree of crimp than the other plurality of continuous filaments.

Example a 11: the absorbent article of embodiments a-a10, wherein the first plurality of continuous filaments comprises a first cross-sectional shape and the second plurality of continuous filaments comprises a second cross-sectional shape, wherein the first cross-sectional shape and the second cross-sectional shape are different.

Example a 12: the absorbent article of embodiments a-a11, wherein the MD and/or CD characteristic differences comprise a plurality of apertures extending through the web material from the first surface to the second surface.

Example a 13: the absorbent article of embodiments a-a12, wherein the MD and/or CD characteristic differences comprise tufts or corrugations, each of which comprises a distal end disposed above the first surface.

Example a 14: the absorbent article of embodiments a-a12, wherein the MD and/or CD characteristic differences comprise tufts or corrugations, each of which comprises a distal end disposed below the second surface.

Example a 15: the absorbent article of embodiment a-a14, wherein the first plurality of filaments or the second plurality of filaments comprise a softness additive.

Example a 16: the absorbent article of embodiments a-a11, wherein the MD and/or CD characteristic differences comprise a plurality of apertures extending through the first layer.

Example a 17: the absorbent article of embodiments a-a16, wherein the first layer comprises a first color and the second layer comprises a second color, and wherein the second color is a different color.

Example a 18: the absorbent article of embodiment a-a17, wherein the web of material forms a portion of the topsheet, a portion of the backsheet, and/or a portion of an optional layer interposed between the topsheet and the backsheet.

Example a 18: the web of materials of embodiments a-a5 and a7-a18, further comprising a third layer comprising a third plurality of filaments, wherein the third layer is different from the first layer and/or the second layer, and wherein the third layer is integrally formed with the first layer and the second layer, wherein the third plurality of filaments comprises fine denier fibers.

Example B: an absorbent article comprising a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet; a liquid impervious web of material comprising at least a first layer and a second layer integrally formed with the first layer, the first layer comprising a plurality of first filaments and the second layer comprising a plurality of second filaments, wherein the liquid impervious web of material comprises a Z-direction characteristic difference and an MD and/or CD characteristic difference, and wherein the liquid impervious web of material performs the barrier function of the absorbent article.

Example B1: the absorbent article of embodiment B, wherein the liquid impervious web of material forms a portion of the backsheet.

Example B2: the absorbent article of embodiments B-B1 wherein the first plurality of filaments comprises a hydrophobic melt additive.

Example B3: the absorbent article of embodiments B-B2, wherein the first plurality of filaments comprises a filament denier that is less than the filament denier of the second plurality of filaments.

Example B4: the absorbent article of embodiments B-B3, further comprising a third layer integrally formed with the first layer and the second layer, wherein the second layer is disposed between the first layer and the third layer, and wherein the second plurality of filaments comprises one of melt blown, electrospun, or melt fibrillated.

Example B5: the absorbent article of embodiment B4, wherein the third layer comprises a third plurality of filaments, and wherein the third plurality of filaments comprises a hydrophobic melt additive.

Example B6: the absorbent article of embodiment B-B5, further comprising a pair of longitudinal sides and a pair of end edges joining the pair of longitudinal sides on opposite ends of the absorbent article, and a pair of barrier cuffs extending longitudinally adjacent the longitudinal sides of the absorbent article, and wherein the web of material forms a portion of the barrier cuffs.

Example C: an absorbent article comprising a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet, and a web of material comprising a first surface and an opposing second surface, a first layer comprising a first plurality of filaments, and a second layer integrally formed with the first layer comprising a second plurality of filaments, the first plurality of filaments comprising a hydrophobic melt additive, and the second layer being more hydrophilic than the first layer, wherein a plurality of apertures extend from the first surface through the second surface.

Example C1: the absorbent article of embodiment C, wherein the web of material further comprises a plurality of MD and/or CD characteristic differences selected from at least one of: an outer tuft, a tunnel tuft, a nested tuft, an embossed portion, a bond site, a hole, or a corrugation.

Example C2: the absorbent article of embodiments C-C1, wherein the web of material comprises apertures disposed in a first zone oriented longitudinally with respect to the web of material.

Example C3: the absorbent article of embodiments C1-C2, wherein the MD and/or CD characteristic differences are disposed in the second zone and the third zone oriented longitudinally with respect to the web of material.

Example C4: the absorbent article of embodiment C3, wherein the second zone and the third zone are longitudinally flanked by the first zone, and wherein the difference in MD and/or CD characteristics comprises at least one of an outer tuft, a tunnel tuft, or a nested tuft.

Example C5: the absorbent article of embodiments C2-C4, wherein the first zone is laterally oriented to occupy a central region of the absorbent article.

Example C6: the absorbent article of embodiment C5, wherein the second zone and the third zone are laterally flanked by the first zone.

Example C7: the absorbent article of embodiments C1-C6, wherein the MD and/or CD characteristic differences each comprise a distal end and a sidewall, wherein the MD and/or CD characteristic differences are oriented in the positive Z-direction such that the distal end is disposed above the first surface, and the sidewall connects the first surface and the distal end.

Example C8: the absorbent article of embodiment C1-C6, wherein the MD and/or CD characteristic differences each comprise a distal end and a sidewall, wherein the MD and/or CD characteristic differences are oriented in the negative Z-direction such that the distal end is disposed below the first surface and the sidewall connects the second surface and the distal end.

Example C9: the absorbent article of embodiments C-C8 wherein the second plurality of filaments comprises a hydrophilic melt additive.

Example C10: the absorbent article of embodiments C-C9 wherein the first plurality of filaments comprises a polyethylene or polypropylene polymer and wherein the second plurality of filaments comprises polylactic acid, polyethylene terephthalate, or nylon.

Example C11: the absorbent article of any one of embodiments C-C10, wherein the web of material forms a portion of the topsheet.

Example D: an array of disposable absorbent articles, each of the disposable absorbent articles comprising a chassis comprising a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet; and optionally barrier cuffs extending longitudinally along the chassis; and optionally a pair of wings extending laterally outboard of the chassis, the array of disposable absorbent articles further comprising: a first plurality of disposable absorbent articles comprising a first web of material having integrally formed first and second layers, the first web of material forming at least one of: a portion of the topsheet, a portion of the backsheet, a portion of the absorbent core of the first plurality of disposable absorbent articles, wherein the first layer is different from the second layer; a second plurality of disposable absorbent articles comprising a second web of material having integrally formed third and fourth layers, the second web of material forming at least one of: a portion of the topsheet, a portion of the backsheet, or a portion of the absorbent core of the second plurality of disposable absorbent articles, wherein the third layer is different from the fourth layer, wherein the first web of material is different from the second web of material.

Example D1: the array of disposable absorbent articles of embodiment D wherein the first web of material has a higher surface energy than the second web of material.

Example D2: the array of disposable absorbent articles of embodiments D-D1 wherein the first layer is more hydrophilic than the third layer.

Example D3: the array of disposable absorbent articles of embodiments D-D2, wherein the first plurality of disposable absorbent articles comprises adult incontinence products, and wherein the second plurality of disposable absorbent articles comprises feminine hygiene pads.

Example D4: the array of disposable absorbent articles of embodiments D-D3 further comprising a third plurality of disposable absorbent articles, wherein each of the third plurality of disposable absorbent articles comprises a third web of material having integrally formed fifth and sixth layers, the third web of material forming at least one of: a portion of the topsheet, a portion of the backsheet, or a portion of the absorbent core of the third plurality of disposable absorbent articles, wherein the fifth layer is different from the sixth layer, and wherein the third web of material is different from the first web of material and the second web of material.

Example E: a method of making a disposable absorbent article, the method comprising the steps of: obtaining a web of material having a first layer comprising a first plurality of continuous filaments and a second layer comprising a second plurality of continuous filaments, such that the second layer and the first layer are integrally formed, and wherein the first plurality of continuous filaments is different from the second plurality of continuous filaments; creating a plurality of discontinuities on at least a portion of a web of material; attaching a web of material to a backsheet; and disposing the absorbent core between the web of material and the backsheet.

Example E1: the method of embodiment E, wherein the plurality of discontinuities comprise holes.

Example E2: the method of embodiments E-E1 wherein the first plurality of continuous filaments differs from the second plurality of continuous filaments in at least one of: surface energy, filament size, filament cross-sectional shape, filament crimp, filament composition, coefficient of friction, and color.

Example E3: the method of embodiments E-E2, wherein the step of creating the plurality of discontinuities in the web of material creates the plurality of discontinuities in a fluid handling layer disposed between the web of material and the absorbent core.

Example F: an absorbent article comprising a topsheet, a backsheet, and an absorbent core disposed therebetween, and a web of material comprising a first surface and an opposing second surface, a first layer and a second layer integrally formed with the first layer, the first layer having a lower surface energy than the second layer.

Example F1: the absorbent article of embodiment F, wherein the first layer comprises a film and the second layer comprises a nonwoven fabric.

Example F2: the absorbent article of embodiment F, wherein the first layer comprises a nonwoven fabric and the second layer comprises a nonwoven fabric.

Example F3: the absorbent article of embodiments F-F2, wherein the first layer and/or the second layer includes MC and/or CD characteristic differences that include at least one of: holes, bond sites, tunnel clusters, packed clusters, nested clusters, hybrid clusters, embossed portions, ridges and grooves, or corrugations.

Example F4: the absorbent article of embodiments F-F3, wherein the web of material forms a portion of a topsheet of the absorbent article.

Example F5: the absorbent article of embodiments F-F4 wherein the web of material comprises at least two zones wherein the difference in MD and/or CD characteristics in a first zone is different than the difference in MD and/or CD characteristics in a second zone.

Method for bonding layers

The first and second layers may be joined together by any suitable method. First, the filaments from the individual spinning boxes (or also from the meltblowing boxes) become increasingly braided to some extent during the laying of the filaments onto the already laid layer or layers. And as previously described, the nonwoven layers may be bonded together via primary bond sites. Typically, the primary bond sites are thermal point bonds that fuse or compress all of the layers of the web material together in discrete areas to form film-like discrete primary bond sites. These primary bond sites are not among the differences in MD and/or CD characteristics and/or Z-direction as described herein.

Some suitable examples of more intimate and strong bonding means include calender bonding or thermal point bonding (selected from the various possible patterns or patterns), through air bonding, hydroentangling, and the like, each of which is well known in the art; or a combination of those bonding means. Another suitable example includes needle punching, which is well known in the art. In addition, the attachment of the first nonwoven layer to the second nonwoven layer may also be accomplished by a number of different processes.

For those webs of the present invention that are desired to have filled tufts, care should be taken to consider the percentage of bond area between the first and second layers. The inventors have found that for crimped filaments, too low a calender bond area does not allow good formation of the filled and outer tufts, contrary to common wisdom that lower bond areas are generally thought to be beneficial for texturing of spunbond webs. In addition, too low a calender bond area produces a web of material with low strength and poor abrasion resistance. However, a too high calender bond area will reduce the filament length between adjacent bonds, which will inhibit the amount of stretching and/or displacement possible. In particular, too high a calender bond area inhibits movement of the filaments such that the crimped filaments have very limited ability to stretch when subjected to the localized Z-direction pushing described herein for forming the filled tufts and the outer tufts. In such configurations, the coiled filaments must undergo plastic deformation or fracture once the amount of stretch exceeds the amount of applied process strain. The present inventors have found that a calender bond area of greater than about 10% and less than about 18% allows for a good balance of filament mobility and free filament length available for stretching, yet still provides sufficient strength in the web material for handling the crimped filaments and for abrasion and tear resistance in use.

In some forms of the invention, a web material comprising crimped filaments may comprise a calender bond area between about 10% and about 18% or between about 12% and 16%, specifically including all values within these ranges or any range resulting therefrom. Webs of materials of the present invention that do not include coiled filaments can include a calender bond area of between about 5% and about 30%, between about 10% and about 20%, specifically including all values within these ranges and any ranges produced thereby. The bonds may be shaped as dots, diamonds, ovals, or any other suitable shape, and may be arranged in any suitable pattern to provide the desired mechanical properties.

Disposable absorbent article

As previously mentioned, the web material of the present invention may comprise any suitable portion of a disposable absorbent article. Some examples include a topsheet, a backsheet, barrier cuffs, an intermediate layer between the topsheet and the absorbent core and/or an intermediate layer between the backsheet and the absorbent core.

Referring to fig. 33, an absorbent article 1710 that may utilize a web of material as described herein may be a sanitary napkin/pantiliner. As shown, the sanitary napkin 1710 can comprise a chassis comprising a liquid pervious topsheet 1714, a liquid impervious or substantially liquid impervious backsheet 1716 and an absorbent core 1718 positioned between the topsheet 1714 and the backsheet 1716. Sanitary napkin 1710 can include flap portions 1720 that extend outwardly relative to a longitudinal axis 1780 of sanitary napkin 1710. The sanitary napkin 1710 can also include a lateral axis 1790. The wing portion 1720 may be joined to the topsheet 1714, the backsheet 1716, and/or the absorbent core 1718. Sanitary napkin 1710 may also include a front edge 1722, a back edge 1724 longitudinally opposite the front edge 1722, a first side edge 1726, and a second side edge 1728 laterally opposite the first side edge 1726. The longitudinal axis 1780 can extend from a midpoint of the front edge 1722 to a midpoint of the back edge 1724. Lateral axis 1790 may extend from a midpoint of first side edge 1728 to a midpoint of second side edge 1728. Sanitary napkin 1710 may also be provided with additional features often found in sanitary napkins, as is well known in the art. In some forms of the invention, the flaps may be provided with zones of extensibility as described in U.S. patent 5,972,806.

Any suitable absorbent core known in the art may be used. The absorbent core 1718 can be any absorbent member that is generally compressible, conformable, non-irritating to the wearer's skin, and capable of absorbing and retaining liquids such as urine, menses, and/or other body exudates. The absorbent core 1718 can be manufactured from a wide variety of liquid-absorbent materials commonly used in disposable absorbent articles, such as comminuted wood pulp, which is generally referred to as airfelt. The absorbent core 1718 can include superabsorbent polymers (SAP) and less than 15%, less than 10%, less than 5%, less than 3%, or less than 1% airfelt, or no airfelt at all. Examples of other suitable absorbent materials include creped cellulose wadding; including coform meltblown polymers; chemically stiffened, modified or cross-linked cellulosic fibers; tissue, including tissue packaging and tissue laminates; absorbing the foam; an absorbent sponge; a superabsorbent polymer; an absorbent gelling material; or any similar material or combination of materials.

The configuration and construction of the absorbent core 1718 may vary (e.g., the absorbent core may have varying caliper zones, a hydrophilicity gradient, a superabsorbent gradient, or lower average density and lower average basis weight acquisition zones; or may comprise one or more layers or structures). In some forms, the absorbent core 1718 may include one or more channels, such as two, three, four, five, or six channels.

The absorbent core 1718 of the present disclosure may include, for example, one or more adhesives to help secure the SAP or other absorbent material within the core wrap and/or to ensure the integrity of the core wrap, particularly when the core wrap is made of two or more substrates, the core wrap may extend to a larger area than is required for having one or more absorbent materials contained therein.

Absorbent cores comprising relatively high amounts of SAP with various core designs are disclosed in the following patents: U.S. Pat. No. 5,599,335 to Goldman et al, EP 1,447,066 to Busam et al, WO 95/11652 to Tanzer et al, U.S. patent publication 2008/0312622A1, and WO 2012/052172 to Van Malderen.

Other forms and more details regarding channels and pockets of no or substantially no absorbent material, such as SAP, in the absorbent core are discussed in more detail in U.S. patent application publications 2014/0163500, 2014/0163506, and 2014/0163511, all of which were published on 6/12 of 2014.

The absorbent article 1710 may include additional layers between the topsheet 1714 and the absorbent core 1718. For example, the absorbent article 1710 may include a secondary topsheet and/or acquisition layer positioned between the topsheet 1714 and the absorbent core 1718.

The backsheet may comprise a liquid impermeable film. The backsheet may be impervious to liquids (e.g., bodily fluids) and may typically be manufactured from a thin plastic film. However, the backsheet is typically capable of allowing vapors to escape from the disposable article. In one embodiment, a microporous polyethylene film may be used for the backsheet. Suitable microporous polyethylene films are manufactured by Mitsui Toatsu Chemicals, Inc (celebrity house, japan) and sold under the trade name PG-P.

One suitable material for the backsheet may be a liquid impermeable thermoplastic film having a thickness of about 0.012mm (0.50 mil) to about 0.051mm (2.0 mils), including, for example, polyethylene or polypropylene. Typically, the backsheet may have about 5g/m²To about 35g/m²Basis weight of (c). However, it should be noted that other liquid impermeable flexible materials may be used as the backsheet. As used herein, "flexible" refers to materials that are compliant and readily conform to the general shape and contours of the wearer's body.

The backsheet may generally be positioned adjacent the outward-facing surface of the absorbent core and may be joined to the outward-facing surface by any suitable attachment means known in the art. For example, the backsheet may be secured to the absorbent core by a uniform continuous layer of adhesive, a patterned layer of adhesive, or an array of separate lines, spirals, or spots of adhesive. Exemplary, but non-limiting, adhesives include those manufactured by h.b.fuller corporation (st.paul, minn., u.s.a.) and sold as HL-1358J. One example of a suitable attachment means comprising an open pattern network of adhesive filaments is disclosed in U.S. Pat. No. 4,573,986 entitled "Disposable Waste-content gateway" to Minetola et al, 3.4.1986. Another suitable attachment means includes a plurality of adhesive filaments twisted into a helical pattern, as illustrated by the apparatus and methods shown in the following patents: us patent 3,911,173 issued to Sprague, jr, on 7/10/1975; us patent 4,785,996 to Ziecker et al, 11/22/1978; and U.S. patent 4,842,666 to Werenicz, 6.27.1989. Alternatively, the attachment means may comprise a thermal bond, a thermal fusion bond, a pressure bond, an ultrasonic bond, a dynamic mechanical bond, or any other suitable attachment means or combination of these attachment means. Additionally, the backsheet may also be secured to the topsheet by any of the attachment means/methods described above.

Another example of a disposable absorbent article that may utilize the web material of the present invention is a diaper, which includes non-refastenable pants and/or refastenable diapers. The diaper may have a construction similar to that of a sanitary napkin. Exemplary diapers are described below.

Reference is made to fig. 34, which is a plan view of an exemplary absorbent article, which is a diaper 1900 in its flat, uncontracted state (i.e., with the elastic-induced contraction pulled out), with portions of the structure being cut away to more clearly show the construction of the diaper 1900, and with its wearer-facing surface facing the viewer. The diaper is shown for illustrative purposes only, as the present disclosure can be used to make a variety of diapers and other absorbent articles.

The absorbent article may comprise a liquid pervious topsheet 1924, a liquid impervious backsheet 1925, an absorbent core 1928 positioned at least partially between the topsheet 1924 and the backsheet 1925, and barrier leg cuffs 1934. The absorbent article may also include a liquid management system ("LMS") 1950 (shown in fig. 35), which in the example shown includes a distribution layer 1954 and an acquisition layer 1952, both of which are also discussed below. In various forms, the acquisition layer 1952 may instead distribute bodily exudates, and the distribution layer 1954 may instead acquire bodily exudates, or both layers may distribute and/or acquire bodily exudates. The LMS 1950 may also be provided as a single layer or two or more layers. The absorbent article may also include an elasticized gasketing cuff 1932 that is joined to the chassis of the absorbent article, typically via the topsheet and/or backsheet, and is substantially planar with the chassis of the diaper.

The figure also shows typical taped diaper components such as a fastening system comprising adhesive tabs 1942 or other mechanical fasteners attached towards the back edge of the absorbent article 1920 and cooperating with landing zones 1944 on the front of the absorbent article 1920. The absorbent article may also include other typical elements not shown, such as a back elastic waist feature and a front elastic waist feature.

The absorbent article 1920 can include a front waist edge 1910, a back waist edge 1912 longitudinally opposite the front waist edge 1910, a first side edge 1903, and a second side edge 1904 laterally opposite the first side edge 1903. The front waist edge 1910 is the edge of the absorbent article 1920 that is intended to be placed toward the front of the user when worn, and the back waist edge 1912 is the opposite edge. When the absorbent article 1920 is worn upward on the wearer, the front waist edge 1910 and the back waist edge together form a waist opening. The absorbent article 1920 can have a longitudinal axis 1980 that extends from the lateral midpoint of the front waist edge 1910 to the lateral midpoint of the back waist edge 1912 of the absorbent article 1920 and divides the absorbent article 1920 into two substantially symmetrical halves with respect to the longitudinal axis 1980, wherein the article lies flat and is viewed from the wearer-facing surface, as shown in figure 34. The absorbent article may also have a lateral axis 1990 that extends from the longitudinal midpoint of the first side edge 1903 to the longitudinal midpoint of the second side edge 1904. The length L of the absorbent article 1920 can be measured along the longitudinal axis 1980 from the front waist edge 1910 to the back waist edge 1912. The crotch width of the absorbent article 1920 may be measured along the lateral axis 1990 from the first side edge 1903 to the second side edge 1904. The absorbent article 1920 may include a front waist region 1905, a back waist region 1906, and a crotch region 1907. The front waist region, the back waist region, and the crotch region each define 1/3 of the longitudinal length of the absorbent article. The front and rear portions may also be defined on opposite sides of the lateral axis 1990.

The topsheet 1924, backsheet 1925, absorbent core 1928, and other article components may be assembled in a variety of configurations, particularly by gluing or heat embossing, for example. Exemplary diaper configurations are generally described in U.S. Pat. No. 3,860,003, U.S. Pat. No. 5,221,274, U.S. Pat. No. 5,554,145, U.S. Pat. No. 5,569,234, U.S. Pat. No. 5,580,411, and U.S. Pat. No. 6,004,306.

The absorbent core 1928 may include an absorbent material and a core wrap enclosing the absorbent material in an amount of from 75% to 100%, at least 80%, at least 85%, at least 90%, at least 95%, or at least 99%, all by weight of the absorbent material, specifically reciting all 0.1% increments within the above-specified ranges and all ranges formed therein or thereat. The core wrap may generally comprise two materials, base or nonwoven materials 16 and 16', for the top and bottom sides of the core.

The absorbent core 1928 may include one or more channels, shown in figure 34 as the four channels 1926,1926 'and 1927,1927'. Additionally or alternatively, the LMS 1950 may include one or more channels, shown in fig. 34-36 as channel 1949,1949'. In some forms, the channels of the LMS 1950 may be positioned within the absorbent article 1920 such that they are aligned with, substantially aligned with, overlap, or at least partially overlap the channels of the absorbent core 1928. These and other components of the absorbent article will now be discussed in more detail.

The topsheet 1924 is the portion of the absorbent article that is in direct contact with the wearer's skin. The topsheet 1924 may be joined to the backsheet 1925, core 1928, and/or any other layers, as is well known to those skilled in the art. Typically, the topsheet 1924 and backsheet 1925 are joined directly to one another at some locations (e.g., on or near the perimeter of the article) and are joined indirectly by joining them directly to one or more other elements of the absorbent article 1920 at other locations.

The backsheet 1925 is generally that portion of the absorbent article 1920 that is positioned adjacent the garment-facing surface of the absorbent core 1928 and which prevents, or at least inhibits, the bodily exudates absorbed and contained therein from soiling articles such as bed sheets and undergarments. The backsheet 1925 is generally impervious, or at least substantially impervious, to liquids (e.g., urine, runny feces) but permeable to vapors to allow the diaper to be "breathable". The backsheet may be or comprise a thin plastic film, such as a thermoplastic film having a thickness of about 0.012mm to about 0.051mm, for example. Exemplary backsheet films include those manufactured by Tredegar Corporation, headquartered, VA, and sold under the trade name CPC2 film. Other suitable backsheet materials may include breathable materials that permit vapors to escape from the absorbent article 1920 while still preventing, or at least inhibiting, body exudates from passing through the backsheet 1925. Exemplary breathable materials may include materials such as woven webs, nonwoven webs, and composite materials, such as film-coated nonwoven webs, microporous films, and monolithic films.

The backsheet 1925 may be joined to the topsheet 1924, the absorbent core 1928, and/or any other elements of the absorbent article 1920 by any attachment method known to those skilled in the art. Suitable attachment methods have been described above for methods for joining the topsheet 1924 to other elements of the absorbent article 1920.

As used herein, the term "absorbent core" refers to the individual components of an absorbent article having a maximum absorbent capacity and comprising absorbent material. The absorbent core may comprise a core wrap or core bag (hereinafter "core wrap") enclosing the absorbent material. The term "absorbent core" does not include LMS or any other component of the absorbent article that is neither an integral part of the core wrap nor disposed within the core wrap. The absorbent core may comprise, consist essentially of, or consist of: a core wrap, an absorbent material as defined below, and a glue enclosed within the core wrap. Pulp or airfelt may also be present in the core wrap and may form part of the absorbent material. The absorbent core perimeter (which may be the perimeter of the core wrap) may define any suitable shape, such as, for example, a "T", "Y", "hourglass" or "dog bone" shape. The periphery of an absorbent core having a generally "dog bone" or "hourglass" shape may taper along its width toward the central or "crotch" region of the core. In this way, the absorbent core may have a relatively narrow width in the area of the absorbent core intended to be placed in the crotch region of the absorbent article.

The absorbent core 1928 of the present disclosure may include an absorbent material with a high content of superabsorbent polymers (abbreviated herein as "SAP") encapsulated within a core wrap. The SAP content may represent 70% to 100% or at least 70%, 75%, 80%, 85%, 90%, 95%, 99% or 100% by weight of the absorbent material comprised in the core wrap. SAPs useful in the present disclosure may comprise a variety of water-insoluble, but water-swellable polymers capable of absorbing large amounts of fluids. For the purpose of evaluating the percentage of SAP in the absorbent core, the core wrap is not considered as an absorbent material. The remainder of the absorbent material in the core 1928 may be airfelt.

"absorbent material" refers to materials that have some absorbent or liquid retention properties, such as SAP, cellulosic fibers, and synthetic fibers. Generally, the glue used to make the absorbent core does not have absorbent properties and is not considered an absorbent material. As mentioned above, the SAP content may represent more than 80%, such as at least 85%, at least 90%, at least 95%, at least 99%, and even up to and including 100% of the weight of the absorbent material contained within the core wrap. This provides a relatively thin core compared to conventional cores, which typically comprise e.g. between 40-60% SAP and a high content of cellulose fibres or airfelt. The absorbent material may comprise less than 15% or less than 10% by weight natural or synthetic fibers, less than 5% by weight, less than 3% by weight, less than 2% by weight, less than 1% by weight, or may even be substantially free or free of natural and/or synthetic fibers, specifically reciting all 0.1% increments within the specified ranges and all ranges formed therein or thereby. The absorbent material may comprise little or no airfelt (cellulose) fibers, in particular the absorbent core may comprise less than 15%, 10%, 5%, 3%, 2%, 1% airfelt (cellulose) fibers by weight, or may even be substantially free, or free, of cellulose fibers, specifically reciting all 0.1% increments within the specified ranges and all ranges formed therein or thereby.

The absorbent core 1928 may also include a generally planar top side and a generally planar bottom side. As seen from the top in plan view as shown in fig. 34, the core 1928 may have a longitudinal axis 80' that substantially corresponds to the longitudinal axis 80 of the absorbent article. The absorbent material may be distributed towards the front side in a higher amount than towards the back side, since more absorbency may be required in the front of a particular article. The absorbent article may have a non-uniform basis weight or a uniform basis weight in any portion of the core. The core wrap may be formed from two nonwoven materials, substrates, laminates, or other materials 1916,1916', which may be sealed at least partially along the sides of the absorbent core. The core wrap may be sealed at least partially along its front side, back side, and both longitudinal sides such that substantially no absorbent material leaks out of the absorbent core wrap. The first material, substrate, or nonwoven fabric 1916 may at least partially surround the second material, substrate, or nonwoven fabric 1916' to form a core wrap. The first material 1916 can surround a portion of the second material 1916' adjacent the first and second side edges 1903 and 1904.

Cores comprising relatively high amounts of SAP with various core designs are disclosed in U.S. patent 5,599,335(Goldman), EP 1,447,066(Busam), WO 95/11652(Tanzer), U.S. patent publication 2008/0312622a1 (huntorf), and WO 2012/052172(Van Malderen).

The absorbent material may be one or more continuous layers present within the core wrap. Alternatively, the absorbent material may be constituted by a separate bag or strip of absorbent material enclosed within the core wrap. In the first case, the absorbent material may be obtained, for example, by applying a single continuous layer of absorbent material. A continuous layer of absorbent material, in particular SAP, may also be obtained by combining two or more absorbent layers having a discontinuous absorbent material application pattern, wherein the resulting layers are substantially continuously distributed over an area of absorbent particulate polymer material, as disclosed in U.S. patent application publication 2008/0312622a1 (Hundorf). The absorbent core 1928 may include a first absorbent layer and a second absorbent layer. The first absorbent layer may include a first material 1916 and a first layer 1961 of absorbent material, which may be 100% SAP or less. The second absorbent layer may include a second material 1916' and a second layer 1962 of absorbent material, which may also be 100% or less SAP.

The fibrous thermoplastic adhesive material 1951 may at least partially contact the absorbent material 1961,1962 in the landing zone and at least partially contact the materials 1916 and 1916' in the junction zone. This gives the cellulosic layer thermoplastic binder material 591 a substantially three-dimensional structure which is itself a substantially two-dimensional structure with a relatively small thickness compared to the dimensions in the length and width directions. The fibrous thermoplastic adhesive material may thus provide cavities to cover the absorbent material in the landing zone, which may be 100% or less SAP, to immobilize the absorbent material.

The core wrap may be made of a single substrate, material, or nonwoven folded around the absorbent material, or may comprise two (or more) substrates, materials, or nonwovens attached to each other. Typical attachments are so-called C-wraps and/or sandwich wraps. In a C-wrap, the longitudinal and/or transverse edges of one of the substrates are folded over the other substrate to form a flap. These flaps are then bonded to the outer surface of the other substrate, typically by gluing. Other techniques may be used to form the core wrap. For example, the longitudinal and/or transverse edges of the substrate may be bonded together and then folded under the absorbent core 28 and bonded in that position.

The core wrap may be sealed at least partially along all sides of the absorbent core such that substantially no absorbent material leaks out of the core. By "substantially free of absorbent material", it is meant less than 5%, less than 2%, less than 1%, or about 0% by weight of absorbent material escapes the core wrap. The term "sealing" should be understood in a broad sense. The seal need not be continuous along the entire perimeter of the core wrap, but may be discontinuous along part or all of it, such as formed by a series of seal points spaced in a line. The seal may be formed by gluing and/or heat bonding.

The core wrap may also be formed from a single substrate that can enclose the absorbent material in the wrap and be sealed along the front and back sides of the core and one longitudinal seal.

The absorbent article may comprise a pair of barrier leg cuffs 1934. Each barrier leg cuff may be formed from a sheet of material that is bonded to the absorbent article such that it may extend upwardly from the interior surface of the absorbent article and provide improved containment of liquids and other body exudates adjacent the juncture of the wearer's torso and legs. The barrier leg cuffs 1934 are defined by a proximal edge 1964 and a free end edge 1966 joined directly or indirectly to the topsheet 1924 and/or backsheet 1925 which are intended to contact the skin of the wearer and form a seal. The barrier leg cuffs 1934 extend at least partially between the front and back waist edges 1910, 1912 of the absorbent article on opposite sides of the longitudinal axis 1980 and are present in at least the crotch region 1907. The barrier leg cuff 1934 may be joined at the proximal edge 1964 with the chassis of the absorbent article by a bond 1965, which may be made by a combination of gluing, fusion bonding, or other suitable bonding processes. The bond 1965 at the proximal edge 64 can be continuous or intermittent. The bond 1965 of the raised section closest to the leg cuff 1934 defines the proximal edge 1964 of the upstanding section of the leg cuff 1934.

The barrier leg cuffs 1934 may be integral with the topsheet 1924 or backsheet 1925 or may be a separate material joined to the chassis of the absorbent article. The material of the barrier leg cuffs 1934 may extend through the entire length of the diaper but may be "adhesively bonded" to the topsheet 1924 toward the front and back waist edges 1910, 1912 of the absorbent article such that in these sections the barrier leg cuff material remains flush with the topsheet 1924.

Each barrier leg cuff 1934 may include one, two or more elastic strands or film strips 1935 near the free end edge 1966 to provide a better seal.

In addition to the barrier leg cuffs 1934, the absorbent article may further comprise gasketing cuffs 1932 joined to the chassis of the absorbent article, in particular to the top sheet 1924 and/or the back sheet 1925, and positioned exteriorly with respect to the barrier leg cuffs 1934. The gasket cuff 1932 may provide a better seal around the wearer's thighs. Each gasketing leg cuff may comprise one or more elastic threads or elements in the chassis of the absorbent article between the topsheet 1924 and the backsheet 1925 in the leg opening area. All or a portion of the barrier leg cuff and/or the gasket cuff may be treated with a lotion or skin care composition. The barrier leg cuffs may be constructed in a number of different configurations, including those described in U.S. patent application publication 2012/0277713.

In one form, the absorbent article may include front ears 1946 and back ears 1940. The ear panel may be an integral part of the chassis, such as formed as a side panel from the topsheet 1924 and/or the backsheet 1925. Alternatively, as presented on fig. 34, the ear panel (1946,1940) may be a separate element attached by gluing, heat embossing, and/or pressure bonding. The back ears 1940 may be stretchable to facilitate attachment of the tabs 1942 to the landing zone 1944 and to facilitate holding the taped diaper in place around the waist of the wearer. The back ears 1940 may also be elastic or extensible to provide a more comfortable and more conformable fit by: the absorbent article is initially conformed to the wearer and remains so throughout the wear long after the absorbent article is loaded with exudates because the elasticized ears allow the sides of the absorbent article to expand and contract.

One function of the LMS 1950 is to quickly acquire fluid and distribute it to the absorbent core 1928 in an efficient manner. The LMS 1950 may include one or more layers that may form an integral layer or may remain as discrete layers that may be attached to one another. The LMS 1950 may include two layers: a distribution layer 1954 and an acquisition layer 1952 disposed between the absorbent core and the topsheet, although the present disclosure is not limited to such configurations.

The LMS 1950 may include SAP as this may slow down fluid acquisition and distribution. In other forms, the LMS may be substantially free (e.g., 80%, 85%, 90%, 95%, or 99% free) or completely free of SAP. For example, the LMS may also comprise one or more of a variety of other suitable types of materials, such as open-cell foams, air-laid fibers, or carded resin-bonded nonwovens. Suitable examples of LMS are described in, for example, WO 2000/59430(Daley), WO 95/10996(Richards), us 5,700,254(McDowall), and WO 02/067809 (Graef).

The LMS 1950 may include a distribution layer 1954. The distribution layer 1954 can include, for example, at least 50% or more by weight of cross-linked cellulose fibers. The crosslinked cellulosic fibers can be crimped, twisted, or crimped, or a combination thereof (including crimped, twisted, and crimped). This type of material is disclosed in U.S. patent publication 2008/0312622a1 (huntorf).

The LMS 1950 may alternatively or additionally include an acquisition layer 1952. The acquisition layer 1952 may be disposed between, for example, a distribution layer 1954 and a topsheet 1924. The acquisition layer 1952 may be or may include a nonwoven material, such as an SMS or SMMS material, comprising a spunbond layer, a meltblown layer and another spunbond layer or alternatively a carded, chemically bonded nonwoven. The acquisition layer 1952 may comprise air-laid or wet-laid cellulose, cross-linked cellulose, or synthetic fibers, or blends thereof. The acquisition layer 1952 may comprise a roll web of synthetic fibers (which may be processed, such as by solid state forming, to increase void space), or a combination of synthetic fibers and cellulosic fibers, which are bonded together to form a high loft material. Alternatively, the acquisition layer 1952 may comprise an absorbent open cell foam. The nonwoven material may be latex bonded.

The LMS 1950 of the absorbent article 1920 may include channels that may generally enable the absorbent article to better conform to the anatomy of the wearer, resulting in increased freedom of movement and reduced gaps. One or more of the channels of the LMS 1950 may be configured to work with various channels in the absorbent core 1928, as described above. In addition, the channels in the LMS 1950 may also provide increased void space to retain and distribute urine, BM, or other bodily exudates within the absorbent article, resulting in reduced leakage and skin contact. The channels in the LMS 1950 may also provide internally available indicia (especially when highlighted by physical differences in texture, color, and/or pattern) to facilitate proper alignment of the absorbent article on the wearer. Thus, such physical differences may be visually and/or tactilely noticeable, for example.

As previously mentioned, the web material of the present invention may be used as a topsheet for disposable absorbent articles, examples of which include the aforementioned sanitary napkins 1810 and diapers 1920.

The web of material of the present disclosure may be used as a component of an absorbent article. More than one web of material may be used in a single absorbent article. In such a context, the web of material may form at least a portion of the topsheet; a topsheet and an acquisition layer; a topsheet and a distribution layer; an acquisition layer and a distribution layer; a topsheet, an acquisition layer, and a distribution layer; an outer cover; a negative film; an outer cover and a backsheet, wherein the film (non-apertured layer) forms the backsheet and the nonwoven web forms the outer cover; a leg cuff; an ear or side panel; a fastener; a waistband; a belt or any other suitable portion of an absorbent article. The number of layers in the web material may also be determined by the particular use of the web material.

In some forms, an additional layer may be positioned between the topsheet and the absorbent core. For example, a secondary topsheet, acquisition layer, and/or distribution layer (each of which is known in the art) may be positioned between the topsheet and the absorbent core of the absorbent article.

Absorbent article array

As previously mentioned, the web material of the present invention can be used in a plurality of absorbent articles. And as previously mentioned, the web material of the present invention can be advantageous for the construction of absorbent articles. Forms of the invention are envisaged in which an array of absorbent articles each comprising a topsheet, a backsheet and an absorbent core disposed therebetween comprises a web of material of the invention. The array includes a first plurality of absorbent articles comprising a first nonwoven web. The first web of material comprises a first layer and a second layer that are integrally formed. The first web of material may form at least a portion of each of the first plurality of absorbent articles, such as a topsheet, a backsheet, an absorbent core. The first and second layers may be different from each other.

The array further includes a second plurality of absorbent articles. Each of the second plurality of absorbent articles comprises a second web of material forming a portion of at least one of: a topsheet, a backsheet and/or an absorbent core. The second web of material may comprise a first layer and a second layer that are integrally formed. The first and second layers may not be the same. The first web of material may be different from the second web of material. And in some forms the first plurality of absorbent articles may comprise a first type of absorbent article and the second plurality of absorbent articles comprises a second type of absorbent article. For example, the first plurality of absorbent articles may comprise adult incontinence articles and the second plurality of absorbent articles comprise pantiliners.

A form of the invention is envisioned in which the first web of material includes an MD/CD gradient that is different from the MD/CD gradient included in the second web of material. For example, adult incontinence articles may be expected to absorb more liquid at a faster rate. Thus, the first nonwoven may include a first plurality of apertures having a first "effective aperture area". The second nonwoven may include a second plurality of apertures having a second "effective aperture area". The first "effective aperture area" may be greater than the second "effective aperture area".

A form of the invention is envisaged in which the array comprises an additional plurality of absorbent articles. Such additional plurality of absorbent articles may comprise a web of material of the present invention. These webs of material may be different from the first web of material and/or the second web of material. Additionally, these webs of material may include an MD/CD gradient that is different from the MD/CD gradient of the first web of material and/or the second web of material.

The basis weight of the web material may vary depending on the use of the web material of the present invention. The basis weight of the web material is typically expressed in grams per square meter (gsm). Depending on the end use of the material 30, the basis weight of the web material may range from about 8gsm to about 100 gsm. For example, the web material of the present invention may have a basis weight of from about 8 to about 40gsm, or from about 8 to about 30gsm, or from about 8 to about 20 gsm. The basis weight of the multi-layer material is the combined basis weight of the component layers and any other added components, such as the web material plus other component layers. Depending on the end use of the material 30, the basis weight of the multi-layer materials of interest herein may range from about 20gsm to about 150 gsm. The web material can have a density of between about 0.01g/cm3 and about 0.4g/cm3 measured at 0.3psi (2 KPa).

Testing

Basis weight test

Using 9.00cm²A large nonwoven substrate sheet, i.e., 1.0cm wide by 9.0cm long. Samples may be cut from consumer products such as wipes or absorbent articles or their packaging materials. The samples must be dry and free of other materials such as glue or dust. The samples were conditioned at 23 ° celsius (+ -2 ℃) and a relative humidity of about 50% (+ -5%) for 2 hours to reach equilibrium. The weight of the cut nonwoven substrate was measured on a balance with an accuracy of 0.0001 g. The mass obtained is divided by the area of the sample to give the mass in g/m²Results in (gsm) meter. The same procedure was repeated for at least 20 samples from 20 identical consumer products or their packaging materials. If the product is consumed orThe packaging material is sufficiently large that more than one sample can be obtained from each consumer product or its packaging material. One example of a sample is a portion of a topsheet of an absorbent article. If local basis weight change tests are performed, those same samples and data are used to calculate and report the average basis weight.

Filament diameter and denier testing

The diameter of the filaments in the nonwoven substrate sample was determined by using a "scanning electron microscope" (SEM) and image analysis software. The magnification is selected to be 500 to 10,000 times such that the filament is suitably magnified for measurement such that at least 3-5 pixels are measured across the filament diameter ("width"). The samples were sputtered with gold or palladium-gold compounds to avoid charging and vibration of the filaments in the electron beam. A manual protocol for determining filament diameter was used. Using a mouse and cursor tool, the edge of a randomly selected filament is searched for and then measured across its width (i.e., the direction of the filament perpendicular to the point) to the other edge of the filament. For non-circular filaments, the area of the cross-section was measured by analyzing the Z-plane cross-section of the filament using image analysis software. The effective diameter is then calculated by calculating the diameter as if the region s were found to be circular. Scaling the calibration image analysis tool provides scaling to obtain the actual reading in micrometers (μm). SEM was therefore used to randomly select several filaments across the nonwoven substrate sample. At least two samples from the nonwoven substrate were cut and tested in this manner. A total of at least 100 such measurements were made and all data were then recorded for statistical analysis. The recorded data were used to calculate the mean value of the filament diameters, the standard deviation of the filament diameters, and the median value of the filament diameters. Another useful statistic is to calculate the number of populations of filaments below a certain upper limit. To determine this statistic, the software was programmed to count how many filament diameters were below an upper limit of the result, and the number (divided by the total number of data and multiplied by 100%) was reported as a percentage below the upper limit, e.g., a percentage below 1 micron diameter or% -submicron.

If the results are intended to be reported in denier, the following calculations are made.

Filament diameter in denier-cross-sectional area (in m 2) density (in kg/m 3)

9000m*1000g/kg。

For round filaments, the cross-sectional area is defined by the following equation:

A＝π*(D/2)^2。

for polypropylene, for example, a density of 910kg/m3 may be used.

Given the filament diameters in denier, the physical round filament diameters in meters (or microns) are calculated from these relationships, and vice versa. We expressed the measured diameter (in microns) of the individual round filaments as D.

Calculating the fiber diameter:

the number average diameter (which is often referred to simply as the y-average diameter) can be determined by the following equation:

the filament cross-sectional shape may also be determined from the cross-sectional image in the above Z-plane. The nonwoven filaments near the first surface of the web material should be evaluated to determine the cross-sectional shape. The cross-sectional shape of the filaments near the first surface of the web material should be recorded. The nonwoven filaments near the second surface of the web material should be evaluated to determine the cross-sectional shape. The cross-sectional shape of the filaments near the second surface of the web material should be recorded.

Specific surface area

The specific surface area of the nonwoven substrates of the present disclosure was determined by Krypton gas adsorption using Micromeritic ASAP 2420 or equivalent instrument, using the continuous saturated vapor pressure (Po) method (according to ASTM D-6556-10), and following the principles and calculations of Brunauer, Emmett and Teller, using Kr-BET gas adsorption techniques including automatic degassing and thermal calibration. Note that the sample should not be degassed at 300 degrees celsius as recommended by the method, but at room temperature. The specific surface area should be in m ²Report in g。

Obtaining samples of nonwoven substrates

Each surface area measurement was obtained from a sample of the nonwoven substrate of the present disclosure totaling 1 g. To obtain 1g of material, multiple samples can be obtained from one or more absorbent articles, one or more packages, or one or more wipes, depending on whether an absorbent article, package, or wipe is being tested. Wet wipe samples will dry at 40 ℃ for two hours or until the liquid does not bleed out of the sample under light pressure. The sample is cut from the absorbent article, package or wipe (depending on whether the absorbent article, package or wipe is to be tested) using scissors in an area free or substantially free of adhesive. An ultraviolet fluorescence analysis chamber is then used on the sample to detect the presence of the adhesive, as the adhesive will fluoresce under this illumination. Other methods of detecting the presence of adhesive may also be used. The area of the sample showing the presence of adhesive was cut from the sample so that the sample was free of adhesive. The samples can now be tested using the specific surface area method described above.

Mass mean diameter

The mass mean diameter of the filaments was calculated as follows:

the mass-average diameter of the steel pipe,

in the formula

The filaments in the sample are assumed to be round/cylindrical.

d_iThe diameter of the ith filament in the sample was measured,

the very small longitudinal section of the filament, in which its diameter is measured, is the same for all filaments in the sample,

m_ithe mass of the ith filament in the sample,

n-the number of filaments in the sample whose diameter is measured,

ρ ═ the density of the filaments in the sample, the same for all filaments in the sample,

V_ithe volume of the ith filament in the sample,

the mass average filament diameter should be reported in μm.

Weight loss test

The "weight loss test" is used to determine the amount of melt additive such as a lipid ester (e.g., Glycerol Tristearate (GTS)) in the nonwoven substrate of the present disclosure. One or more samples of nonwoven substrates having a narrowest sample size of no greater than 1mm were placed in acetone at a ratio of 1g nonwoven substrate sample/100 g acetone using a reflux flask system. The sample was first weighed before being placed in the reflux flask, and then the mixture of sample and acetone was heated to 60 ℃ for 20 hours. The sample was then removed and air dried for 60 minutes and the final weight of the sample was determined. The formula used to calculate the weight percent of lipid ester in the sample is weight percent lipid ester ([ initial mass of sample-final mass of sample ]/[ initial mass of sample ]) × 100%.

Hole Feret angle test

Pore diameter, effective open area, and inter-pore distance measurements are obtained from sample images acquired using a planar scanner. The scanner is capable of scanning in reflection mode at 6400dpi resolution and 8 bit gray scale (a suitable scanner is Epson Perfection V750 Pro from Epson America Inc. (Long Beach CA), or equivalent). The scanner is connected to a computer running an image analysis program (a suitable program is ImageJ version 1.47 or equivalent, National Institute of Health (USA)). The sample image is distance calibrated against the acquisition pattern of a ruler certified by NIST. The steel frame was used to mount the specimen, which was then backed with black glass tiles (P/N11-0050-30, available from HunterLab, Reston, Va.) prior to the acquisition of the specimen image. The resulting image is then thresholded, the open pore region is separated from the sample material region, and analyzed using an image analysis program. All tests were conducted in a conditioning chamber maintained at about 23 ± 2 ℃ and about 50 ± 2% relative humidity.

Sample preparation：

To obtain a sample, the absorbent article is glued to a rigid flat surface in a planar configuration. Any leg elastic strands may be cut away to facilitate the flattening of the article. The samples were mounted using a linear steel frame (100 mm square, 1.5mm thick with a 60 mm square opening). A steel frame is taken and a double-sided adhesive tape is placed on the bottom surface around the interior opening. The release paper of the tape was removed and the steel frame was attached to the nonwoven substrate of the article to be evaluated. The frames are aligned such that they are parallel and perpendicular to the Machine Direction (MD) and cross-machine direction (CD) of the nonwoven substrate. A razor blade was used to cut the nonwoven substrate from the underlying layer of the article around the outer periphery of the shelf. The sample is carefully removed so that its longitudinal and lateral extensions are retained to avoid distortion of the hole or any other discontinuity. Samples can be removed from the underlying layer using a cryospray, such as Cyto-Freeze, Control Company (Houston, TX), if necessary. Five replicates obtained from five substantially similar articles were prepared for analysis. If the nonwoven substrate of interest is too small to accommodate steel framing, the frame dimensions are correspondingly reduced for the purpose of removing the sample without distortion of the apertures and/or any other discontinuities, while leaving openings of sufficient size to allow scanning of a significant portion of the nonwoven substrate. Nonwoven substrate raw materials were prepared for testing by: it was extended or activated under the same process conditions to the same extent as it would be used on an absorbent article and then attached in its extended state to the steel frame used for testing as described above. Prior to testing, the samples were conditioned for 2 hours at about 23 ℃ ± 2 ℃ and about 50% ± 2% relative humidity.

Image acquisition：

The ruler was placed on the scanner bed, oriented parallel to the side of the scanner glass, and the lid was closed. A calibration image of the ruler was acquired in reflection mode at a resolution of 6400dpi (about 252 pixels/mm) and 8 bit grayscale, under a field of view corresponding to the dimensions of the interior of the steel frame. The calibration image is saved as an uncompressed TIFF format file. The lid is lifted and the ruler is removed. After the calibration image is obtained, all samples are scanned under the same conditions and measurements are made based on the same calibration file. Next, the sample on the shelf was placed flat on the center of the scanning bed with the outer facing surface of the sample facing the glass surface of the scanner. The sample is oriented so that the sides of the rack are aligned parallel and perpendicular to the sides of the glass surface of the scanner so that the resulting sample image will have a MD that runs vertically from top to bottom. Place black glass tile on top of frame, cover the sample, close the lid and take the scan image. The remaining four replicates were scanned in a similar manner. All images are cropped, if necessary, to a rectangular field of view circumscribing the aperture area and the document is restored.

Effective open area calculation：

A calibration image file is opened in the image analysis program and a linear distance calibration is performed using the imaged ruler. The distance calibration scale will be applied to all subsequent sample images prior to analysis. The sample image is opened and the distance scale is set in the image analysis program. The 8-bit histogram (0 to 255, one binary/GL) is observed and the minimum population gray-level value (GL) located between the dark pixel peak of the hole and the brighter pixel peak of the sample material is identified. The threshold value of the image is set to the minimum gray level value to generate a binary image. In the binary image, the holes appear black with a GL value of 255; and the sample appeared white with a GL value of 0.

Each of the discrete hole regions is analyzed using an image analysis program. Measuring and recording all of the individual well areas to the nearest 0.01mm²Including a partial hole along the edge of the image. The discarding area is less than 0.3mm²Any of (a) and (b). When stray fibers cross the boundary of the hole, areas below 0.3mm can be demonstrated²Is difficult to measure specifically. And such apertures having that small area are considered insignificant for the contribution of the effective aperture area. The sum of the remaining aperture areas (including the whole aperture and part of the aperture) is taken, divided by the total area included in the image and multiplied by 100. This value was recorded as the effective open area% to the nearest 0.01%.

The remaining four sample images were analyzed in a similar manner. For five replicates, the mean effective area value% was calculated and reported to the nearest 0.01%.

Effective aperture area and absolute Feret angle：

The calibration image (containing the ruler) file is opened in the image analysis program. The resolution of the original image was adjusted from 6400dpi to 640dpi (approximately 25.2 pixels/mm) using bicubic interpolation. Linear distance calibration was performed using an imaged ruler. The distance calibration scale will be applied to all subsequent sample images prior to analysis. The sample image is opened in the image analysis program. The resolution of the original image was adjusted from 6400dpi to 640dpi (about 25.2 pixels/mm) using bicubic interpolation. A distance scale is set. The 8-bit histogram (0 to 255, one binary/GL) is observed and the minimum population of Gray Level (GL) values located between the dark pixel peaks of the pores and the lighter pixel peaks of the sample material are identified. The threshold value of the image is set to the minimum gray level value to generate a binary image. In the binary image, the holes appear black with a GL value of 255; and the sample appeared white with a GL value of 0. Then, two morphological operations are performed on the binary image. First, shut down (dilation operation followed by erosion operation, iteration number 1, pixel count 1) removes stray filaments within the aperture. Second, on (erosion operation followed by dilation operation, iteration number 1, pixel count 1) removes isolated black pixels. The edges of the image are lined during the ablation step to ensure that black border pixels remain during the operation. Finally, any remaining voids encapsulated within the black hole region are filled.

Each of the discrete hole regions is analyzed using an image analysis program. Excluding measurement of partial holes along the image edges during the analysis so that only complete holes are measured. All individual hole areas, perimeters, ferter diameters (length of hole) were measured and recorded along with corresponding orientation angles from 0 to 180 degrees and the ferter diameter was minimized (width of hole). Record the area of each hole (to the nearest 0.01mm)²) Circumference and Ferrett diameter (length and width, to the nearest 0.01mm), in order toAnd angle (to the nearest 0.01 degrees). The discarding area is less than 0.3mm²Any of (a) and (b). The number of remaining holes was recorded, divided by the area of the image, and recorded as the hole density value. The orientation angle of the holes aligned with the MD (vertical in the image) will have an angle of 90 degrees. A hole with a positive slope increasing from left to right will have an angle between zero and 90 degrees. A hole with a negative slope that decreases from left to right will have an angle between 90 degrees and 180 degrees. The absolute hole angle was calculated using a single hole angle by subtracting 90 degrees from the original orientation angle and taking its absolute value. In addition to these measurements, the value of the aspect ratio of each individual hole was calculated by dividing the length of the hole by its width. This analysis was repeated for each of the remaining four repeat images. Using all well values recorded from the replicates, statistical mean and standard deviation of each valid well size measurement were calculated and reported. The Relative Standard Deviation (RSD)%, of each pore size measurement was calculated and reported by dividing the standard deviation by the mean and multiplying by 100.

Inter-hole distance measurement：

The mean, standard deviation, median, and maximum distance between wells can be measured by further analyzing the binary image, which is analyzed for well scale measurements. First, after the morphological operation, a copy of the resized binary image is obtained and a Voronoi operation is performed using an image analysis program. This produces a cell image defined by lines having pixels equidistant to the boundary of the two nearest image holes, where the pixel values are output from the Euclidean Distance Map (EDM) of the binary image. An EDM is generated when each inter-hole pixel in the binary image is replaced with a value equal to the pixel distance from the nearest pattern hole. Next, background zeros are removed to enable statistical analysis of the distance values. This is accomplished by dividing the Voronoi cell image by itself using an image calculator to produce a 32-bit floating point image, where all cell lines have a value of one, and the remainder of the image is identified as a non-number (NaN). Finally, using an image calculator, the image is multiplied by the original Voronoi cell image to produce a 32-bit floating point image, with distance values along the cell lines preserved and all zero values replaced with NaN. The pixel distance value is then converted to the actual inter-well distance by multiplying the value in the image by the pixel resolution of the image (about 0.04 mm/pixel) and then multiplying the image again by 2, since the value represents the midpoint distance between wells. The mean, standard deviation, median and maximum interpore distance of the images were measured and calculated to the nearest 0.01 mm. The procedure was repeated for all replicate images. The relative standard deviation% (RSD) of the interpore distance was calculated by dividing the standard deviation by the mean and multiplying by 100.

Pore aspect ratio and area

The apertures of the web material of the present disclosure can have an aspect ratio (ratio of longest visible axis to shortest visible axis of elliptical apertures) greater than one, such as greater than two, greater than 3, greater than 5, or greater than 10, but typically less than 15. The pattern of apertures in the web material may comprise apertures having more than one aspect ratio, such as two or more distinct clusters or a substantially continuous aspect ratio distribution having a slope greater than zero. In addition, the aperture pattern may include apertures having more than two effective aperture areas, such as two or more distinct populations, or a distribution having aperture areas with a slope greater than zero. The Relative Standard Deviation (RSD) of the pore aspect ratio may be at least about 15%, at least about 25%, at least about 30%, or at least about 40%, or at least about 45%.

Degree of filament crimp

The crimp of the filaments in the nonwoven fabric was measured from 3D x radiation sample images obtained on a micro CT instrument (one suitable instrument is Scanco μ CT 50, available from Scanco Medical AG, Switzerland, or equivalent). The micro CT instrument is a cone beam micro-tomography X-ray photographic device with a shielding cabin. A maintenance-free x-ray tube is used as the source of radiation with an adjustable diameter focus. The x-ray beam passes through a sample, wherein some of the x-rays are attenuated by the sample. The degree of attenuation is related to the quality of the material through which the x-rays pass. The transmitted x-rays continue on to the digital detector array and generate 2D projection images of the sample. A 3D image of the sample is generated by collecting several single projection images of the sample (as it is rotated), which are then reconstructed into a single 3D image. The instrument is connected to a computer via an interface, which runs software to control image acquisition and save raw data, the 3D image is then analyzed using image analysis software (one suitable software package is Avizo 3D software from FEI (Hillsboro, OR), OR equivalent).

Sample preparation

To obtain a sample for measurement, a single layer of dried base material was flattened and punched out into a circular piece with a diameter of 16 mm. Care should be taken to avoid folds, wrinkles or tears when selecting a sampling location.

If the substrate material is a layer of an absorbent article, such as a topsheet, backsheet nonwoven, acquisition layer, distribution layer, or other component layer; the absorbent article is taped to a rigid flat surface in a planar configuration. Carefully separating the single substrate layer from the absorbent article. If necessary, a surgical scalpel and/or a cryogenic spray (such as Cyto-Freeze, Control Company (Houston TX)) may be used to remove the base layer from the additional underlying layer, thereby avoiding any longitudinal and lateral extension of the material. Once the substrate layer is removed from the article, a sample is punched out as described above.

Image acquisition

The micro-CT instrument was set up and calibrated according to the manufacturer's instructions. The sample was placed in a suitable holder between two rings of low density material having an 8mm inner diameter. This would allow the central portion of the sample to be placed horizontally and scanned without having any other material directly adjacent to its upper and lower surfaces. The measurement values should be acquired in this area. The 3D image field of view is about 20mm on each side in the xy plane, with a resolution of about 5000 by 5000 pixels, and with a sufficient number of 4 micron thick slices, which are collected to fully encompass the z direction of the sample. The reconstructed 3D image resolution contains isotropic voxels of 4 microns. Images were acquired with the source at 45kVp and 88 μ A without an additional low energy filter. These current and voltage settings can be optimized to produce maximum contrast of projection data with sufficient x-ray transmission through the sample, but once optimized, remain constant for all substantially similar samples. A total of 1200 projection images were obtained with an integration time of 1000ms and 4 averages. The projection images are reconstructed into 3D images and saved in 16 bit RAW format to save the full detector output signal for analysis.

Image processing

Loading the 3D image into the image analysis software. The 3D image is thresholded at a value that separates and removes the background signal due to air, but retains the signal from the sample fibers within the substrate. Four 0.8mm by 0.8mm regions were selected in the xy plane and multiplied by the sample thickness in the z direction. These regions are selected such that they avoid thermal bonding of the nonwoven. To estimate fiber curvature within the double layer nonwoven fabric, the z-direction was divided into three equal parts. To avoid layer boundaries, only the top and bottom thirds were cut and analyzed.

The cropped 3D image is processed to track the central axis of the fiber to create a "skeleton" network of fiber paths. The fiber path is then segmented at any intersection of fibers. For example, two fibers intersecting at a cross would be divided into four segments. After all segments are identified, each segment is further divided into segments as follows. From the start of the segment, the fibre path is traversed to a point along the path at which the start path point and the current path point may be connected by a linear link of exactly 200 μm length. The length of the segment path between the start and end points of the link is the edge length of the link segment. The process repeats using the current waypoint as a new starting waypoint and continues traversing the fiber path to the next waypoint, which may be connected by a linear link of exactly 200 μm in length. The segments are divided into segments in this manner until the wiring can no longer be adapted. Discarding any remaining segment lengths. In addition, if a segment is not long enough to fit the wire, the segment is also discarded. In this manner each fiber section of the 3D scaffold is divided into segments and the average edge length of all segments is calculated and recorded to the nearest micron.

Each of the four images cut from the top side of the nonwoven fabric was processed and the total average edge length was calculated and reported as the curvature of the top side to the nearest micron. Two, the four bottom side cropped images were processed and the total average edge length was calculated and reported as the curvature of the bottom side to the nearest micron.

Surface energy/contact angle method

The contact angle on the substrate is determined by: ASTM D7490-13 modified with specific details as described herein was used using a goniometer and appropriate image analysis software (one suitable instrument is FTA200, First Ten antibodies, Portsmouth, VA, or equivalent) equipped with a 1mL capacity air-tight syringe with a 27 gauge blunt-tipped stainless steel needle. Two test fluids were used: reagent type II water (distilled) according to ASTM Specification D1193-99, and 99 +% purity diiodomethane (both available from Sigma Aldrich (st. louis, MO)). Based on the Owens-Wendt-Kaelble formula, the contact angles obtained from these two test fluids can also be used to calculate the surface energy. All tests were conducted at about 23 ℃. + -. 2 ℃ and about 50%. + -. 2% relative humidity.

The 50mm by 50mm nonwoven substrate to be tested is removed from the article, taking care not to touch the area of interest or otherwise contaminate the surface during acquisition or during subsequent analysis. Prior to testing, the samples were conditioned for 2 hours at about 23 ℃ ± 2 ℃ and about 50% ± 2% relative humidity.

The goniometer was mounted on an anti-vibration table and the platform was leveled according to the manufacturer's instructions. The video capture device must have an acquisition speed that can capture at least 10-20 images from when the droplet touches the sample surface to when it cannot be resolved from the sample surface. A capture rate of 900 images/second is a typical capture rate. Depending on the hydrophobicity/hydrophilicity of the sample, the droplets may or may not quickly wet the surface of the nonwoven fabric sample. In the case of slow acquisition, the image should be acquired until 2% of the drop volume is absorbed into the sample. If the acquisition is extremely fast, the first resolved image should be used (if the second image shows more than 2% volume loss).

The sample is placed on the goniometer platform and the hypodermic needle is adjusted to a distance from the surface recommended by the instrument manufacturer (typically 3 mm). The position of the sample is adjusted, if necessary, to place the target site under the needle. The video device is focused so that a sharp image of the droplets on the sample surface can be captured. Image acquisition is started. Deposit 5. mu.L. + -. 0.1. mu.L droplets onto the sample. If there is visible distortion of the droplet shape due to motion, it is repeated at a different but equivalent target location. Two angular measurements of the drop were made from the image with 2% drop volume loss (one measurement for each drop edge). If the contact angles on the two edges differ by more than 4 deg., the value should be excluded and the test repeated at an equivalent location on the sample. Five additional equivalent sites were identified on the sample and a total of 6 measurements (12 angles) were repeated. The arithmetic mean of this side of the sample is calculated and reported to the nearest 0.01 °. In a similar manner, the contact angle of a 6 drop on the opposite side of the sample (12 angles) was independently measured and reported to the nearest 0.01 °.

To calculate the surface energy, the contact angles of both water and diiodomethane must be tested as described above. The values for each test fluid were then substituted into two separate expressions of the Owens-Wendt-Kaelble formula (one for each fluid). This results in two equations and two unknowns which are then solved to obtain the dispersion and polar components of surface tension.

Owens-Wendt-Kaelble formula:

wherein:

theta ═ average contact angle of test liquid on test specimen

γ_lAnd gamma_sSurface tension of the test liquid and the test specimen (respectively) in dyn/cm,

γ^dand gamma^pDispersion and polar component of surface tension in dyn/cm (respectively).

When a dispersion solvent such as diiodomethane is used, the Owens-Wendt-Kaelble formula is simplified to the following form since the polar component is zero:

using the values from the table and the theta (measured) for diiodomethane, the equation can be solved to obtain the dispersion component (gamma) of the surface energy^d _s). The values from the table and theta (measured) and calculated value (gamma) of water are now used^d _s) The Owens-Wendt-Kaelble formula can be solved to obtain the polar component (gamma) of the surface energy^p _s)。γ^d _s+γ^p _sThe sum of (a) is the total solid surface tension and the surface tension is reported to the nearest 0.1 dyn/cm.

Filament composition

The fiber composition was identified using FTIR microscopy. One suitable system allows for the spatial separation and visualization of the fibers of interest, followed by collection of local FTIR spectra using a "total reflection" or "attenuated total reflection" (ATR) objective (an exemplary system is an Olympus BX-51 microscope with IlluminatIR II infrared microprobe and PixeLink camera available from Smith Detection (Edgewood, Md.). the instrument is calibrated and operated according to the instructions from the vendor of the particular instrument.

If necessary, the nonwoven of interest is removed from the product using a cryogenic spray (such as Cyto-Freeze, Control Company, Houston TX). Under magnification, the fibers were removed from the outermost layer of the first side of the spun melt sample using tweezers. If the fibers are bicomponent fibers, a diagonal cut is made across the fibers to expose the core. The fibers were mounted on a microscope slide and the slide was placed on the stage of the FTIR microscope. The sample fiber is moved under the objective lens and the field of view is focused on the fiber. Move to the area where no sample is present and collect a blank FTIR spectrum. The fiber was moved back under the objective lens and the FTIR spectra of the fiber were collected. If the fiber is a bicomponent fiber, the spectra of both the sheath and the core are collected. The background subtracted spectrum is compared to the library spectrum for identification.

In a similar manner, fibers were removed from within the outermost layer of the second side of the spunmelt sample and FTIR spectra were collected for identification. A total of three fibers from each surface of the nonwoven fabric were collected and analyzed to confirm identification.

The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Rather, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm".

Each document cited herein, including any cross-referenced or related patent or application, is hereby incorporated by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with any disclosure or claims herein or that it alone, or in combination with any other reference or references, teaches, suggests or discloses any aspect of this invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

Claims

1. A disposable absorbent article (1710,1900) having a wearer-facing surface and a garment-facing surface, a longitudinal axis (1780,1980), and a lateral axis (1790,1990) perpendicular to the longitudinal axis, the disposable absorbent article further comprising:

a topsheet (1714,2014) forming at least a portion of the wearer-facing surface;

a backsheet (1716,1925) forming at least a portion of the garment-facing surface;

an absorbent core (1718,1928) disposed between the topsheet and the backsheet;

a web of material (10) having a first surface (50) and a second surface (52) opposite the first surface, a machine direction generally parallel to the longitudinal axis and a cross direction generally parallel to the lateral axis and perpendicular to the machine direction, and a Z-direction perpendicular to a plane containing the machine direction and the cross direction, the web of material further comprising:

A first layer (20) comprising a first plurality of filaments, the first layer forming a portion of the first surface; and

a second layer (30) comprising a second plurality of filaments, the second layer forming a portion of the second surface;

wherein the first layer and the second layer are integrally formed, wherein the web of material comprises a Z-direction characteristic difference and a machine direction and/or cross direction characteristic difference from the first layer to the second layer, and wherein the web of material forms a portion of the disposable absorbent article;

wherein the Z-direction feature difference comprises: surface energy.

2. The absorbent article of claim 1, further comprising a plurality of apertures extending from the first surface of the web of material to the second surface of the web of material.

3. The absorbent article according to claim 1 or 2, wherein the web of material forms a portion of the topsheet such that the first surface forms a portion of the wearer-facing surface.

4. The absorbent article of claim 1 or 2, further comprising a first zone in the longitudinal/lateral plane and a second zone in the longitudinal/lateral plane, wherein the second zone has a difference in longitudinal or lateral characteristics that is different from the first zone.

5. The absorbent article of claim 4, wherein the first zone comprises a different texture than the second zone.

6. The absorbent article of claim 4, wherein the first zone includes a plurality of discontinuities extending from the first surface in the positive Z direction.

7. The absorbent article of claim 4, wherein the second zone comprises a plurality of apertures.

8. The absorbent article of claim 4, wherein the first zone comprises a plurality of discontinuities extending from the second surface in the negative Z direction.

9. The absorbent article of claim 1 or 2, wherein a first plurality of discontinuities extend from the first surface in the positive Z-direction.

10. The absorbent article of claim 1 or 2, wherein a first plurality of discontinuities extend from the second surface in the negative Z-direction.

11. The absorbent article of claim 1 or 2, wherein the first layer has a lower surface energy than the second layer.

12. The absorbent article according to claim 1 or 2, wherein the web of material forms a portion of the garment facing surface.

13. The absorbent article of claim 1 or 2, wherein the web of material comprises a third layer integrally formed with the web of material and disposed on the second surface of the web of material, wherein the first layer comprises a hydrophobic melt additive and the third layer comprises a hydrophilic melt additive such that the first layer has a lower surface energy than the second layer, and wherein the second plurality of filaments have a diameter of less than 8 microns.

14. The absorbent article according to claim 1 or 2, wherein the absorbent article further comprises a pair of longitudinal side edges and a pair of wings extending outboard of the longitudinal side edges or a pair of barrier cuffs extending along the longitudinal side edges, and wherein the web of material forms a portion of the wings or a portion of the pair of barrier cuffs.